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Clutch Release Mechanism: Installation

WARNING: This page is about a different car, the 2002 Nissan Sentra. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement, or clutch damage may occur. Wipe the excess grease off completely, because it may cause the clutch components to slip and shudder.
    Fig 1: Identifying Grease Application Points
    G02022715Courtesy of NISSAN MOTOR CO., U.S.A.
  • Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.
  • Clean old grease and abrasive materials off the grease application area.
  • Apply approximately 1 mm (0.04 in) thick clutch sleeve grease evenly on the sliding part of the clutch lever and the release bearing spring.
  • Apply just enough clutch sleeve grease to fill up the release bearing inner groove.
  • Apply the clutch grease to the clutch disc and the input shaft spline. Install the clutch disc to the input shaft, remove the excess grease around the shaft, and remove the clutch disc.
  • Lightly and evenly apply the clutch sleeve grease on the sliding part of the release bearing, install the release bearing, remove the excess grease around the bearing, and remove the release bearing.
  1. Assemble clutch lever to clutch housing, and insert withdrawal lever.
    2. CAUTION: Spring pins cannot be reused.
    Fig 2: Installing Spring Pins
    G02022716Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Support clutch lever claws with an appropriate wood block, and install new spring pins using a pin punch.
  3. Install release bearing springs to release bearing as shown in Fig 3.
    Fig 3: Installing Release Bearing Springs
    G02022717Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Operate withdrawal lever manually, press clutch spring from both sides, and install release bearing to clutch lever securely.
    Fig 4: Installing Release Bearing
    G02022718Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Make sure a click is heard when release bearing spring is pressed from both sides.
  6. Make sure all parts operate smoothly when operating withdrawal lever.
    Fig 5: Operating Withdrawal Lever
    G02022719Courtesy of NISSAN MOTOR CO., U.S.A.
    7. CAUTION: Remove any excess grease with a shop towel.
  7. Install manual transaxle. Refer to REMOVAL AND INSTALLATION - RS5F70A , REMOVAL AND INSTALLATION - RS5F51A , or REMOVAL AND INSTALLATION - RS6F51H .
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