TRANSMISSION/TRANSAXLE
CONTENTS
SERVICE INFORMATION ............................ 2
PRECAUTIONS ................................................... 2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 2
Precaution ................................................................. 2
PREPARATION ................................................... 3
Special Service Tool ................................................. 3
Commercial Service Tool .......................................... 3
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 4
NVH Troubleshooting Chart ...................................... 4
INSPECTION AND ADJUSTMENT ..................... 5
Inspection and Adjustment ........................................ 5
CLUTCH PEDAL ................................................. 7
Component ................................................................ 7
Removal and Installation ........................................... 7
CLUTCH MASTER CYLINDER ........................... 8
Component ................................................................ 8
Removal and Installation ........................................... 8
Disassembly and Assembly ...................................... 8
Inspection .................................................................. 9
Revision: September 2009 CL-1
SECTION CL CLUTCH
B
CL
E
OPERATING CYLINDER .................................. 10 F
Component ..............................................................10
Removal and Installation .........................................11
Disassembly and Assembly .....................................11 G
Inspection ................................................................11
CLUTCH PIPING ............................................... 12
Component ..............................................................12 H
Removal and Installation .........................................12
CLUTCH RELEASE MECHANISM ................... 13 I
Component ..............................................................13
Removal and Installation .........................................13
Inspection ................................................................14
J
CLUTCH DISC, CLUTCH COVER AND FLY-
WHEEL .............................................................. 16
Component ..............................................................16 K
Removal and Installation .........................................16
Inspection and Adjustment ......................................17
L
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 19
Clutch Control System .............................................19
M
Clutch Master Cylinder (with clutch damper) ...........19
Clutch Operating Cylinder .......................................19
Clutch Disc ..............................................................19
Clutch Cover ............................................................19 N
2010 D22 LCV
 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000005781255

The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution INFOID:0000000005473191

Recommended fluid is brake fluid DOT 3.

Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
When removing and installing clutch piping, use Tool.
Use new brake fluid to clean or wash all parts of master cylin-
der, operating cylinder and clutch damper.
Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air. SBR686C

Revision: September 2009 CL-2 2010 D22 LCV

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000005473192

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number
(Kent-Moore No.) Description
Tool name
CL
ST20600000 Installing clutch cover and clutch disc
(J-26366) a: 16 mm (0.630 in) dia.
Clutch aligning bar b: 22.8 mm (0.898 in) dia.
c: 55 mm (2.17 in) D

E
NT405

ST20050240 Adjusting unevenness of diaphragm spring of

( ) clutch cover
Diaphragm spring adjusting wrench F

ZZA0508D

Commercial Service Tool INFOID:0000000005473193

H

Tool name Description I

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)
J

K
NT360

Bearing puller Removing release bearing

L

NT077

Bearing drift Installing release bearing N

a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.
O

NT474
P

Revision: September 2009 CL-3 2010 D22 LCV

 Symptom
(Possible cause)

gage
SUSPECTED PARTS

Clutch slips
Reference page

Clutch noisy

Revision: September 2009

Clutch pedal spongy
Clutch grabs/chatters

Clutch does not disen-

< SERVICE INFORMATION >

CLUTCH PEDAL (Inspection and Adjustment) CL-5

1
1
NVH Troubleshooting Chart

CLUTCH LINE (Air in line) CL-5

2
MASTER CYLINDER PISTON CUP (Damaged) CL-9

3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11

4
2
ENGINE MOUNTING (Loose) EM-51 (KA24DE), EM-176 (YD25DDTi)

CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-14

1
CLUTCH DISC (Out of true)

5
CLUTCH DISC (Runout is excessive)

5
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned)

5
CL-17
CLUTCH DISC (Oily)

5
2
CLUTCH DISC (Worn out)

2
CLUTCH DISC (Hardened)

2
cause of the problem. Check each part in order. If necessary, repair or replace these parts.

CLUTCH DISC (Lack of spline grease)

5
DIAPHRAGM SPRING (Damaged)

6
3
CL-17
DIAPHRAGM SPRING (Out of tip alignment)
2

6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion) CL-17

7
4
5 FLYWHEEL (Distortion) CL-17

2010 D22 LCV

Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely
INFOID:0000000005473194
 INSPECTION AND ADJUSTMENT
< SERVICE INFORMATION >
INSPECTION AND ADJUSTMENT
A
Inspection and Adjustment INFOID:0000000005473195

CLUTCH PEDAL INSPECTION AND ADJUSTMENT B

1. Check to see if the clutch pedal clevis pin (1) floats freely in the
bore of the clutch pedal (2). It should not be bound by the clevis
(3) or clutch pedal. CL
a. If the clevis pin is not free, check that the pedal stopper bolt (A)
is not applying pressure to the clutch pedal causing the clevis
pin to bind. To adjust, loosen the pedal stopper bolt lock nut (B) D
and turn the pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of E
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the clevis pin is still not free, remove the clevis pin and check F
for deformation or damage. Replace the pin if necessary. Leave
the pin removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
G
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
H
pedal bracket, assist spring, bushing, etc.). Reassemble the
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
3. Check the clutch hydraulic system components (clutch master
AWDIA0513GB
I
cylinder, clutch operating cylinder, Clutch withdrawal lever, clutch release bearing, etc.) for sticking or
binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary. J
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system by following the bleeding
procedure.
K
BLEEDING PROCEDURE
CAUTION:
Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
Do not splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on L
painted areas, wash it away with water immediately.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or M
power bleeder will not purge all of the air from the system.
1. Top off the clutch master cylinder reservoir with the recommended brake fluid "DOT 3".
2. Connect a transparent vinyl tube to the air bleeder valve on the N
clutch operating cylinder as shown.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec- O
onds intervals.
4. With the clutch pedal fully depressed, open the air bleeder valve
to release the air.
P
5. Close the air bleeder valve.
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until no more air bubbles are in SCL203-A
the brake fluid coming out of the vinyl tube attached to the air
bleeder valve.
8. Close the air bleeder valve and tighten to specification.

Revision: September 2009 CL-5 2010 D22 LCV

 INSPECTION AND ADJUSTMENT
< SERVICE INFORMATION >

Air bleeder valve : Refer to CL-10, "Component".

Revision: September 2009 CL-6 2010 D22 LCV

 CLUTCH PEDAL
< SERVICE INFORMATION >
CLUTCH PEDAL
A
Component INFOID:0000000005473196

CL

I
AWDIA0515GB

1. Clutch pedal bracket 2. Fulcrum pin 3. Lock nut J

4. Pedal stopper bolt 5. Clevis pin 6. Pedal stopper rubber
7. Clutch pedal 8. Snap pin 9. Bushing
10. Assist spring A. Refer to CL-8, "Component". K
: Apply lithium-based grease including molybdenum disulphide.

Removal and Installation INFOID:0000000005473197 L

REMOVAL
1. Remove the clutch master cylinder nuts from inside the engine compartment. M
2. Remove the lower instrument panel LH. Refer to IP-10, "Removal and Installation".
3. Remove the snap pin and clevis pin from the clutch pedal.
4. Remove the clutch pedal bracket bolts and then remove the clutch pedal assembly. N

INSTALLATION
Installation is in the reverse order of removal. O
After installation, inspect and adjust the clutch pedal. Refer to CL-5, "Inspection and Adjustment".

Revision: September 2009 CL-7 2010 D22 LCV

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
CLUTCH MASTER CYLINDER
Component INFOID:0000000005473198

AWDIA0514GB

1. Reservoir cap 2. Reservoir 3. Seal

4. Cylinder body 5. Push rod 6. Stopper
7. Stopper ring 8. Seat 9. Lock nut
10. Clevis 11. Piston assembly 12. Piston cup
13. Return spring 14. Spring pin
r: Apply rubber lubricant. S: Apply silicone grease.

Removal and Installation INFOID:0000000005473199

CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe it up immediately and wash the affected
area with water.
REMOVAL
1. Remove the snap pin and clevis pin from the clevis, and separate it from the clutch pedal.
2. Drain the brake fluid from the clutch hydraulic system.
3. Remove the clutch tube from the clutch master cylinder using suitable tool.
4. Remove the clutch master cylinder nuts, and remove the clutch master cylinder from the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
After installation, inspect and adjust the clutch pedal as necessary and bleed the clutch hydraulic system.
Refer to CL-5, "Inspection and Adjustment".
Disassembly and Assembly INFOID:0000000005473200

DISASSEMBLY
1. Remove the spring pin using suitable tool.
2. Remove the reservoir and seal from the cylinder body.
3. Remove the clevis and lock nut, if necessary.
4. Remove the seat, stopper ring, stopper and push rod.
CAUTION:
Carefully remove the push rod to prevent it from popping out and becoming damaged.
NOTE:

Revision: September 2009 CL-8 2010 D22 LCV

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
Remove stopper ring using suitable tool while pushing push rod into cylinder body.
5. Remove the piston assembly and return spring. A

ASSEMBLY
Assembly is in the reverse order of disassembly.
When installing stopper ring, tap in lightly while pushing push rod into cylinder body. B
CAUTION:
Firmly hold the push rod into cylinder body to prevent it from popping out and becoming damaged.
CL
Inspection INFOID:0000000005473201

Check the following items, and replace if necessary.

Rubbing surface of cylinder and piston, for uneven wear, rust or damage D
Piston with piston cup, for wear or damage
Return spring, push rod, stopper and seat for wear or damage
Reservoir, for deformation or damage E

Revision: September 2009 CL-9 2010 D22 LCV

 OPERATING CYLINDER
< SERVICE INFORMATION >
OPERATING CYLINDER
Component INFOID:0000000005473202

KA24DE MODELS

AWDIA0516GB

1. Clutch hose 2. Copper washer 3. Cylinder body

4. Piston spring 5. Piston cup 6. Piston assembly
7. Dust cover 8. Push rod 9. Air bleeder valve
R: Apply rubber grease. r: Apply rubber lubricant. S: Apply silicone grease.

YD25DDTi MODELS

AWDIA0517GB

1. Clutch hose (4WD) 2. Cylinder body 3. Piston spring

4. Piston cup 5. Piston assembly 6. Dust cover
7. Push rod 8. Air bleeder valve 9. Copper washer

Revision: September 2009 CL-10 2010 D22 LCV

 OPERATING CYLINDER
< SERVICE INFORMATION >
10. Clutch hose (2WD)
A
R: Apply rubber grease. r: Apply rubber lubricant. S: Apply silicone grease.

Removal and Installation INFOID:0000000005473203

B
CAUTION:
Do not spill brake fluid on painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
CL
REMOVAL
1. Drain the brake fluid from the clutch hydraulic system.
2. Remove the clutch hose and copper washer from the operating cylinder. D
CAUTION:
Do not reuse copper washer.
3. Remove the operating cylinder bolts, and remove the operating cylinder. E
INSTALLATION
Installation is in the reverse order of removal.
CAUTION: F
Make sure the clutch hose is not bent or twisted.
After installation, bleed the clutch hydraulic system. Refer to CL-5, "Inspection and Adjustment".
G
Disassembly and Assembly INFOID:0000000005473204

DISASSEMBLY
H
Remove the dust cover, push rod, piston assembly and piston spring from the cylinder body.
ASSEMBLY
1. Apply rubber lubricant to the cylinder body inner surface and rubber grease to the piston cup and piston. I
2. Insert the piston assembly and piston spring into the cylinder body.
3. Apply rubber grease to the dust cover and install the push rod and dust cover.
J
Inspection INFOID:0000000005473205

Check the following items, and replace if necessary.

Rubbing surface of cylinder and piston, for uneven wear, rust or damage K
Piston assembly (piston with piston cup), for wear or damage
Piston spring, for wear or damage
Push rod, for wear or damage L
Dust cover, for cracks, deformation or damage

Revision: September 2009 CL-11 2010 D22 LCV

 CLUTCH PIPING
< SERVICE INFORMATION >
CLUTCH PIPING
Component INFOID:0000000005473206

AWDIA0520GB

1. Clutch pedal 2. Clutch master cylinder 3. Clutch pipe

4. Connector (if equipped) 5. Clip 6. Clutch hose
7. Operating Cylinder

Removal and Installation INFOID:0000000005473207

Carefully observe the following during clutch tube removal and installation.
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
Do not reuse the copper washer.
Do not damage the clutch hose, clutch tube or fittings.
Make sure the clutch hose is not bent or twisted.
After installation, bleed the air from the clutch hydraulic system. Refer to CL-5, "Inspection and Adjustment".

Revision: September 2009 CL-12 2010 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
CLUTCH RELEASE MECHANISM
A
Component INFOID:0000000005473208

CL

G
WCIA0441E

1. Holder spring 2. Release bearing sleeve 3. Release bearing

4. Withdrawal lever 5. Dust cover 6. Retainer spring
H

Removal and Installation INFOID:0000000005473209

I
REMOVAL
1. Remove the transmission. Refer to MT-12, "Removal and Installation" (KA24DE) or MT-52, "Removal and
Installation" (YD25DDTi). J
2. Remove the release bearing sleeve assembly, holder spring, and withdrawal lever from inside the clutch
housing.
3. Remove the dust cover. K
4. Remove the retainer spring from the withdrawal lever.
5. Remove the release bearing from the release bearing sleeve
using suitable tool. L

CL145
O
INSTALLATION
Installation is in the reverse order of removal.
P

Revision: September 2009 CL-13 2010 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
When installing release bearing to release bearing sleeve, use
suitable drift.

WCL025

Install retainer spring and holder spring as shown.

SCL217

Clean old grease and abrasive materials off the grease application areas and apply grease to the specified
points as shown.

WCL043

Apply approximately 1mm (0.04 in) thick coat of grease to withdrawal lever and holder spring frictional sur-
faces.
Apply a coat of grease to ball pin contact surface of the withdrawal lever and inner slots of the release bear-
ing. The grease surface should be level with the surrounding area.
Apply a thin coat of clutch sleeve grease to the release bearing frictional surface. After grease application,
install release bearing and wipe off excess grease forced out during bearing installation.
CAUTION:
Do not bring any grease into contact with the clutch disc facing, pressure plate surface, or flywheel
surface.
Before installing transmission to the vehicle, check that each sliding surface slides smoothly by
operating the withdrawal lever.
Inspection INFOID:0000000005473210

Check the following items, and replace if necessary.

Revision: September 2009 CL-14 2010 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
Release bearing, for faulty rotation, damage and proper alignment
Release bearing sleeve, for wear, rust or damage A
Withdrawal lever, for wear, rust or damage
Dust seal, for deformation or cracks
B

CL

SCL733

Revision: September 2009 CL-15 2010 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Component INFOID:0000000005473211

AWDIA0518GB

1. Flywheel 2. Clutch disc 3. Clutch cover

A. Refer to CL-16, "Removal and Installation".
: Apply lithium-based grease including molybdenum disulphide.

Removal and Installation INFOID:0000000005473212

CAUTION:
Do not clean the clutch disc with solvent.
When installing, do not get grease from the main drive shaft onto the clutch disc friction surface.
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to MT-12, "Removal and Installation"
(FS5W71C) or MT-52, "Removal and Installation" (FS5R30A).
2. Remove the clutch cover bolts using power tool and remove the clutch cover and clutch disc.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Do not allow grease to contaminate the clutch facing.
When installing clutch disc and clutch cover, install the Tool and
pre-tighten the bolts. Then tighten the clutch cover bolts according
to the following.

Tool number : ST20630000 (J-26366)

WCIA0172E

KA24DE

Revision: September 2009 CL-16 2010 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
- Tighten the clutch cover bolts to the specified torque in two steps in
numerical order as shown. A

Step 1 : 10 - 20 Nm (1.0 - 2.0 kg-m, 8 - 14 ft-lb)

Step 2 : 22 - 29 Nm (2.2 - 3.0 kg-m, 16 - 22 ft-lb) B

CL

AWDIA0519ZZ

D
YD25DDTi
- Tighten the clutch cover bolts to the specified torque in two steps in
numerical order as shown. E

Step 1 (A) : 10 - 20 Nm (1.0 - 2.0 kg-m, 8 - 14 ft-lb)

Step 2 (B) : 22 - 29 Nm (2.2 - 3.0 kg-m, 16 - 22 ft-lb) F

K
AWDIA0521ZZ

Inspection and Adjustment INFOID:0000000005473213

L
CLUTCH DISC
Check the following items, and replace if necessary.
Clutch disc, for burns, discoloration, oil or grease leakage M
Clutch disc, for wear of facing

Facing wear : Refer to CL-19, "Clutch Disc".

N

ACL063

Revision: September 2009 CL-17 2010 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
Clutch disc, for runout of facing and backlash of spline.

Runout and backlash : Refer to CL-19, "Clutch Disc".

ACL064

CLUTCH COVER
Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height. If unevenness exceeds the limit, adjust the dia-
phragm spring toe height using Tool.

Uneven limit of diaphragm : Refer to CL-19, "Clutch

spring toe height Cover".

Tool number : ST20050240 ( )

SCL466

FLYWHEEL
CAUTION:
Do not allow any magnetic materials to contact the ring gear teeth.
Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.
Check flywheel runout. Refer to EM-55, "Inspection" (KA24DE), or
EM-192, "Inspection After Disassembly" (YD25DDTi).

AEM100

Revision: September 2009 CL-18 2010 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Clutch Control System INFOID:0000000005473214

B
Type of clutch control Hydraulic

Clutch Master Cylinder (with clutch damper) INFOID:0000000005473215

CL

Inner diameter 15.87 mm (5/8 in)

D
Clutch Operating Cylinder INFOID:0000000005473216

Unit: mm (in)
E
Engine KA24DE YD25DDTi
Inner diameter 17.46 (11/16) 19.05 (3/4)

Clutch Disc INFOID:0000000005473217 F

Unit: mm (in)

Engine KA24DE YD25DDTi G

Model 240 250
Facing size 240 x 150 x 3.5 250 x 160 x 3.5
(Outer dia. x inner dia. x thickness) (9.45 x 5.91 x 0.138) (9.84 x 6.30 x 0.138) H
7.75 - 8.25 (0.305 - 0.3248) 8.1 - 8.5 (0.3189 - 0.3346)
Thickness of disc assembly with load
with 4,903 N (500 kg, 1,103 lb) with 7,350 N (750 kg, 1,652 lb)
I
Wear limit of facing surface to rivet head 0.3 (0.012) 0.3 (0.012)
Runout limit of facing 1.0 (0.039) 0.7 (0.028)
Distance of runout check point (from hub center) 115 (4.53) 120 (4.72) J
Maximum backlash of spline (at outer edge of disc) 1.0 (0.039) 1.0 (0.039)

Clutch Cover INFOID:0000000005473218

K
Unit: mm (in)

Engine KA24DE YD25DDTi

L
Model 240 250
2WD 4,903 N (500 kg, 1,103 lb) 7,360 N (751 kg, 1,655 lb)
Set-load
4WD 7,360 N (751 kg, 1,655 lb) M
Diaphragm spring height 38.5 (1.516) 40.5 (1.594)
Uneven limit of diaphragm spring toe height 0.7 (0.028) 0.7 (0.028)
N

Revision: September 2009 CL-19 2010 D22 LCV