C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

E
CONTENTS
PRECAUTIONS .......................................................... 2 CSC (CONCENTRIC SLAVE CYLINDER) ................ 11 F
Precautions for Supplemental Restraint System Removal and Installation ........................................ 11
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REMOVAL ........................................................... 11
SIONER” .................................................................. 2 INSTALLATION ................................................... 11 G
Service Notice or Precautions .................................. 2 CLUTCH PIPING ....................................................... 12
PREPARATION ........................................................... 3 Removal and Installation ........................................ 12
Special Service Tools ............................................... 3 REMOVAL ........................................................... 12
H
Commercial Service Tools ........................................ 3 INSTALLATION ................................................... 12
NOISE, VIBRATION AND HARSHNESS (NVH) CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 13
TROUBLESHOOTING ................................................ 4 Removal and Installation ........................................ 13
NVH Troubleshooting Chart ..................................... 4 COMPONENTS ................................................... 13 I
CLUTCH PEDAL ........................................................ 5 REMOVAL ........................................................... 13
On-vehicle Inspection and Adjustment ..................... 5 INSPECTION AND ADJUSTMENT AFTER
Removal and Installation .......................................... 7 REMOVAL ........................................................... 13 J
COMPONENTS .................................................... 7 INSTALLATION ................................................... 14
REMOVAL ............................................................. 7 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
INSPECTION AFTER REMOVAL ......................... 7 Clutch Control System ............................................ 16
K
INSTALLATION ..................................................... 7 Clutch Pedal ........................................................... 16
CLUTCH FLUID .......................................................... 8 Clutch Disc ............................................................. 16
Air Bleeding Procedure ............................................ 8 Clutch Cover ........................................................... 16
CLUTCH MASTER CYLINDER .................................. 9 L
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9 M

Revision: June 2006 CL-1 2007 Versa

 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” ECS00GVW

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
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 per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal 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
harness connectors.
Service Notice or Precautions ECS00FST

● Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS".
● Never reuse fluid drained from clutch system.
● Be careful not to splash brake fluid on painted areas.
● Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.
● Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.
● If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
der). Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage CSC seal and may cause clutch fluid leakage.
● Do not disassemble clutch master cylinder and CSC.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.

Revision: June 2006 CL-2 2007 Versa

 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS00FSU

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
B
(Kent-Moore No.)
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
( — ) clutch cover CL
Diaphragm spring adjusting wrench

ZZA0508D

KV30101000 Installing clutch cover and clutch disc E

( — ) a: 15.9 mm (0.626 in) dia.
Clutch aligning bar b: 19.8 mm (0.780 in) dia.

ZZA1178D
G
Commercial Service Tools ECS00G57

Tool name Description

H
Power tool Loosening bolts and nuts

PBIC0190E
J

Revision: June 2006 CL-3 2007 Versa

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart ECS00FSV

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.

EM-103
EM-73

CL-13
CL-11
CL-5

CL-8
Reference page

CSC (Concentric slave cylinder) (Worn, dirty or damaged)

CLUTCH PEDAL (Inspection and adjustment)

DIAPHRAGM SPRING (Out of tip alignment)

CLUTCH DISC (Lack of spline grease)
CLUTCH DISC (Runout is excessive)

DIAPHRAGM SPRING (Damaged)

CLUTCH DISC (Dirty or burned)

PRESSURE PLATE (Distortion)

CLUTCH DISC (Lining broken)
ENGINE MOUNTING (Loose)
SUSPECTED PARTS (Possible cause)

CLUTCH DISC (Out of true)

CLUTCH DISC (Hardened)

CLUTCH DISC (Worn out)
CLUTCH LINE (Air in line)

FLYWHEEL (Distortion)
CLUTCH DISC (Oily)
Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1
Symptom Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 5 5 5 5 5 5 6 6 7

Revision: June 2006 CL-4 2007 Versa

 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

A
On-vehicle Inspection and Adjustment ECS00GVX

1. Check to see if the master cylinder rod end floats freely. It

should not be bound by the clutch pedal. B
a. If the rod end is not free, check that the ASCD switch is not
applying pressure to the clutch pedal causing the rod end to
bind. To adjust, disconnect the ASCD switch electrical connector
CL
and turn the ASCD switch.
b. Connect the ASCD switch electrical connector.
c. Verify that the master cylinder rod end floats freely. It should not D
be bound by the clutch pedal.
d. If the rod end is still not free, remove the rod end and check for PCIB1491E
deformation or damage. Leave the rod end removed for step 2.
E
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the pedal up and down to determine if it moves
freely.
F
b. If any sticking is noted, replace the clutch pedal assembly. Re-verify that the master cylinder rod end floats
freely.
3. Adjust clutch interlock switch (1) position so that clearance
G
between clutch pedal (2) and thread end of clutch interlock
switch (1), with clutch pedal fully depressed, is within specifica-
tion (C).
H
Clearance C : 0.74 - 1.96 mm (0.0291 - 0.0772 in)

M
WCIA0594E

Revision: June 2006 CL-5 2007 Versa

 CLUTCH PEDAL

4. Adjust ASCD clutch switch (1) position so that clearance

between clutch pedal (2) and thread end of ASCD clutch switch
(1), with clutch pedal fully released, is within specification (A).
Clearance A : 0.74 - 1.96 mm (0.0291 - 0.0772 in)

WCIA0595E

5. Check the clutch hydraulic system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever and clutch release bearing) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "Air
Bleeding Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.

Revision: June 2006 CL-6 2007 Versa

 CLUTCH PEDAL

Removal and Installation ECS00FSX

COMPONENTS A

CL

I
WCIA0596E

1. Clutch pedal assembly 2. Lock nut 3. Clutch interlock switch

4. ASCD clutch switch 5. Lock nut J

REMOVAL
1. Remove instrument lower finisher. Refer to IP-11, "Removal and Installation" . K
2. Disconnect clutch interlock switch and ASCD clutch switch harness connectors.
3. Remove clutch switch harness clamp from clutch pedal assembly.
4. Disconnect master cylinder rod end from clutch pedal lever. L
5. Remove clutch pedal assembly nuts, and then remove clutch
pedal assembly.
M

PCIB1491E

INSPECTION AFTER REMOVAL

Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found, replace
clutch pedal assembly.
INSTALLATION
Installation is in the reverse order of removal.
● After installing the clutch switches, adjust the switch positions. Refer to CL-5, "On-vehicle Inspection and
Adjustment" .

Revision: June 2006 CL-7 2007 Versa

 CLUTCH FLUID

CLUTCH FLUID PFP:00017

Air Bleeding Procedure ECS00FSY

NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
● Carefully monitor fluid level in reservoir tank during bleeding operation.
● Keep painted surface of body and other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
● First bleed the air from the operating cylinder air bleed
valve (1) and then from the bleed connector air bleed valve.
1. Connect a transparent vinyl tube and container to the air bleeder
valve on the clutch operating cylinder.
2. Fill reservoir tank with new clutch fluid.
3. Depress and release the clutch pedal slowly and fully 15 times
at an interval of 2 to 3 seconds.
4. With pedal depressed, continue the bleeding procedure.

PCIB1494E

5. Push the lock pin (1) of the bleeding connector (2) into the
locked position.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con-
nector (2) when fluid pressure is applied in the tube.

PCIB1495E

6. Slide clutch tube (1) in the direction of the arrow as shown, then
bleed the air from the tube.
Dimension A : 5 mm (0.20 in)
7. Return clutch tube (1) and lock pin (2) to their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 2 to 8 until no bubbles are observed in the clutch
fluid.

PCIB1496E

Revision: June 2006 CL-8 2007 Versa

 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

A
Removal and Installation ECS00FSZ

REMOVAL
1. Use one of the following methods to remove hose from master cylinder.
B
● Drain clutch fluid from reservoir tank and remove hose.

● Remove hose from master cylinder. Immediately plug hose and reservoir tank to prevent clutch fluid
from dripping. CL
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
D
2. Remove master cylinder rod end from clutch pedal assembly.

G
PCIB1491E

3. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). H

PCIB1497E
K
4. Rotate master cylinder clockwise by 45° and remove from the vehicle.
INSTALLATION
L
1. Tilt master cylinder clockwise by 45° and insert it in the mounting
hole. Rotate counterclockwise to secure it. At this time, nipple is
in the up position.
2. Install master cylinder rod end to clutch pedal. M

SCIA1286E

Revision: June 2006 CL-9 2007 Versa

 CLUTCH MASTER CYLINDER

3. Install clutch tube (1) fully into connector of master cylinder (2).
4. Install lock pin (3) fully into connector of master cylinder (2).
5. Fill with new clutch fluid and bleed air from the system. Refer to
CL-8, "CLUTCH FLUID" .
6. After completing this procedure, inspect and adjust the clutch
pedal. Refer to CL-5, "On-vehicle Inspection and Adjustment" .

PCIB1500E

Revision: June 2006 CL-10 2007 Versa

 CSC (CONCENTRIC SLAVE CYLINDER)

CSC (CONCENTRIC SLAVE CYLINDER) PFP:30500

A
Removal and Installation ECS00FT0

CAUTION:
● If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin- B
der). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.
● Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi- CL
ately and wash the affected area with water.
REMOVAL
1. Remove transaxle assembly. Refer to MT-15, "Removal and Installation" . D
2. Remove CSC bolts and the CSC from clutch housing.

G
PCIB1498E

INSTALLATION
H
1. Install CSC to clutch housing and then tighten bolts to specification. Refer to MT-17, "Case and Housing
Components" .
CAUTION:
● Do not reuse CSC.
I
● Do not insert and operate CSC because piston and stopper of CSC components may fall off.

2. Install transaxle assembly. Refer to MT-15, "Removal and Installation" .

J
3. Bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .

Revision: June 2006 CL-11 2007 Versa

 CLUTCH PIPING

CLUTCH PIPING PFP:30650

Removal and Installation ECS00FT1

PCIB1499E

1. Clutch tube 2. Lock pin 3. CSC

4. Clutch damper 5. Master cylinder 6. Clutch pedal

Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Remove lock pin (2) from clutch damper (3).
2. Remove clutch tube (1) from clutch damper (3).
3. Remove clutch damper (3) from bracket (4).

WCIA0597E

INSTALLATION
Installation is in the reverse order of removal.
● Make sure that all tubes are fully installed into connectors.
● Make sure that all connector lock pins are fully installed.
● After installation, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .

Revision: June 2006 CL-12 2007 Versa

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100

A
Removal and Installation ECS00FT2

COMPONENTS
B

CL

G
WCIA0637E

1. Flywheel 2. Clutch disc *1, *2 3. Clutch cover

H
Apply lithium-based grease including molybdenum disulphide.
*1. Do not clean in solvent. *2. When installing, be careful that grease applied to input shaft does not adhere to
clutch disc.
I

CAUTION:
● If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
J
der). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.
● Be careful not to apply any grease to the clutch disc facing, pressure plate surface and flywheel
surface. K

REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to MT-15, "Removal and Installation" . L
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc M
● Check clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline : 1.0 mm (0.039 in)
(at outer edge of disc)
Distance of runout check point : 215 mm (8.46 in)
(from hub center)
● Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
● Measure backlash to clutch disc spline and input shaft spline at
the circumference of clutch disc. If outside the specification,
SCL221
replace clutch disc.
Maximum allowable spline backlash : 1.0 mm (0.039 in)

Revision: June 2006 CL-13 2007 Versa

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

● Use a suitable tool to measure the depth to clutch disc facing

rivet heads. If it exceeds the allowable wear limit, replace clutch
disc.
Wear limit of facing : 0.3 mm (0.012 in)
surface to rivet head

SCL229

Clutch Cover
Check clutch cover installed on vehicle for unevenness of diaphragm
spring toe height.
Uneven limit : 0.7 mm (0.028 in) or less

Tool number A : ST20050240 ( — )

● If out of limit, adjust the height using Tool (A).
● Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
● Worn thrust ring will generate a beating noise when tapped at PCIB1502E

the rivet with a suitable tool.

● Broken thrust ring will make a clinking sound when cover is shaken up and down.

● If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
● Check contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
● Check the flywheel runout. Refer to EM-103, "FLYWHEEL
DEFLECTION (M/T MODELS)" .
CAUTION:
Measure flywheel outer face (not on knock pin and clutch cover
mounting hole).

PBIC2646E

INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and dust caused by abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or shudder. If it adheres to CSC seal, it
will cause clutch fluid leakage. Wipe off excess grease.
3. Install clutch disc using tool.
Tool number : KV30101000 ( — )
4. Install clutch cover. Pre-tighten clutch cover bolts.

Revision: June 2006 CL-14 2007 Versa

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

5. Tighten clutch cover bolts evenly in two steps in the order

shown. Refer to CL-13, "COMPONENTS" . A
6. Install transaxle assembly. Refer to MT-15, "Removal and Instal-
lation" .
B

CL

PCIB1772E

Revision: June 2006 CL-15 2007 Versa

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Clutch Control System ECS00FT3

Type of clutch control Hydraulic

Clutch Pedal ECS00FT4

Clearance ″A″ between clutch pedal and ASCD switch threaded

0.74 - 1.96 mm (0.0291 - 0.0772 in)
end while clutch pedal is fully released.
Clearance ″C″ between clutch pedal and clutch interlock switch
0.74 - 1.96 mm (0.0291 - 0.0772 in)
threaded end while clutch pedal is fully depressed.

Clutch Disc ECS00FT5

Model 225
Facing size (outer dia. × inner dia. × thickness) 225 mm × 160 mm × 3.2 mm (8.86 in × 6.30 in × 0.126 in)
Thickness of disc assembly with load 7.2 - 7.6 mm (0.283 - 0.299 in) with 5,394 N (550 kg, 1,213 lb)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 215 mm (8.46 in) dia.
Maximum spline backlash (at outer edge of disc) 1.0 mm (0.039 in)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)

Clutch Cover ECS00FT6

Set-load 5,394 N (550 kg, 1,213 lb)

Diaphragm spring lever height 20 - 22 mm (0.79 - 0.87 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less

Revision: June 2006 CL-16 2007 Versa