TRANSMISSION & DRIVELINE
CL
CONTENTS
PRECAUTION ............................................... 3
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 3
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................... 3
Service Notice or Precautions for Clutch .................. 4
PREPARATION ............................................ 5
PREPARATION ................................................... 5
Special Service Tools ................................................ 5
Commercial Service Tools ........................................ 5
Sealant or/and Lubricant ........................................... 6
SYMPTOM DIAGNOSIS ............................... 7
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 7
NVH Troubleshooting Chart ...................................... 7
PERIODIC MAINTENANCE .......................... 9
CLUTCH PEDAL ................................................. 9
Inspection and Adjustment ........................................ 9
CLUTCH FLUID ..................................................11
Inspection ................................................................ 11
Draining ................................................................... 11
Refilling ................................................................... 11
Air Bleeding ............................................................. 12
REMOVAL AND INSTALLATION ............... 14
CLUTCH PEDAL ................................................14
Exploded View ........................................................ 14
Removal and Installation ......................................... 14
Inspection and Adjustment ...................................... 15
CLUTCH MASTER CYLINDER ..........................17
Exploded View ........................................................ 17
Revision: November 2016 CL-1
A
B
SECTION
CLUTCH C
CL
E
Removal and Installation .........................................17 F
Disassembly and Assembly .....................................19
Inspection ................................................................21
G
OPERATING CYLINDER .................................. 22
QR25DE .....................................................................22
QR25DE : Exploded View .......................................22 H
QR25DE : Removal and Installation ........................22
QR25DE : Disassembly and Assembly ...................22
QR25DE : Inspection ...............................................24
I
YD25DDTI ..................................................................24
YD25DDTi : Exploded View .....................................25
YD25DDTi : Removal and Installation .....................25 J
YD25DDTi : Disassembly and Assembly ................25
YD25DDTi : Inspection ............................................27
YS23DDT/YS23DDTT (M9T) .....................................27 K
YS23DDT/YS23DDTT (M9T) : Exploded View ........28
YS23DDT/YS23DDTT (M9T) : Removal and In-
stallation ..................................................................28 L
YS23DDT/YS23DDTT (M9T) : Disassembly and
Assembly .................................................................28
YS23DDT/YS23DDTT (M9T) : Inspection ...............30 M
CLUTCH PIPING ............................................... 31
Exploded View .........................................................31
Hydraulic Layout ......................................................32 N
Removal and Installation .........................................33
Inspection ................................................................34
O
CLUTCH RELEASE MECHANISM ................... 35
GASOLINE ENGINE MODELS ..................................35
GASOLINE ENGINE MODELS : Exploded View ....35 P
GASOLINE ENGINE MODELS : Removal and In-
stallation ..................................................................35
GASOLINE ENGINE MODELS : Inspection ............36
DIESEL ENGINE MODELS .......................................36
DIESEL ENGINE MODELS : Exploded View ..........37
2017 D23
 DIESEL ENGINE MODELS : Removal and Instal-
lation ....................................................................... 37
DIESEL ENGINE MODELS : Inspection ................ 39
CLUTCH DISC AND CLUTCH COVER ............. 40
Exploded View ........................................................ 40
Removal and Installation ........................................ 40
Inspection ............................................................... 41
Revision: November 2016 CL-2
SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 43
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 43
General Specification .............................................. 43
Clutch Pedal ............................................................ 43
Clutch Master Cylinder ............................................ 43
Clutch Disc .............................................................. 43
Clutch Cover ........................................................... 44
2017 D23
 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000014266285

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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 SR and SB section of
this Service Manual.
WARNING: CL
• 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, it is recommended that all mainte-
nance and repair be performed by an authorized NISSAN/INFINITI dealer. E
• Improper repair, 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 SR section.
F
• 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.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
Ignition 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 I
battery or batteries, and wait at least three minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000014266286
J

NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
K
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If L
a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. M
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE N
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged. O
2. Carry the Intelligent Key or insert it to the key slot and turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- P
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.

Revision: November 2016 CL-3 2017 D23

 PRECAUTIONS
< PRECAUTION >
Service Notice or Precautions for Clutch INFOID:0000000014266287

WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
CAUTION:
• Clutch fluid use refer to MA-23, "Fluids and Lubricants".
• Never reuse drained clutch fluid.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• When removing clutch tube, use a flare nut wrench.
• When installing clutch tube, use a flare nut torque wrench (A)
(Commercial service tool).
• Use new clutch fluid to clean or wash all parts of master cylin-
der.
• Use new clutch fluid to clean or wash all parts of operating
cylinder.
• Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
• Turn the ignition switch OFF and disconnect the battery nega-
tive terminal before removal and installation the work.
• During disassembly or assembly, keep inside of master cylin-
JPFIA0061ZZ
der clear of dust or dirt.
• During disassembly or assembly, keep inside of operating cylinder clear of dust or dirt.

Revision: November 2016 CL-4 2017 D23

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000014266288
B

The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.) C
Tool name
KV30101400 Installing release bearing
( — ) a: 51 mm (2.01 in) dia. CL
Drift b: 44 mm (1.73 in) dia.

ZZA0838D

F
KV31100300 Removing and installing spring pin
( — ) a: 4.5 mm (0.177 in) dia.
Pin punch
G

H
NT410

ST20050240 Adjusting unevenness of diaphragm spring

( — ) lever
Diaphragm adjusting wrench I

ZZA0508D

Commercial Service Tools INFOID:0000000014266289 K

Tool name Description L

Clutch aligner Installing clutch disc

N
MCIB0404E

Revision: November 2016 CL-5 2017 D23

 PREPARATION
< PREPARATION >
Tool name Description
Puller Removing release bearing

NT077

Power tool Loosening nuts and bolts

PIIB1407E

Sealant or/and Lubricant INFOID:0000000014266290

Name Description Note

Multi-purpose grease Clutch disc (On spline only) —
Rubber grease Rubbing surfaces of piston assembly (Operating cylinder) —
Silicone grease Contact surface of push rod (Operating cylinder) —
Rubber lubricant Cylinder body (Clutch master cylinder and operating cylinder) —
Lithium based grease Clevis pin —

Revision: November 2016 CL-6 2017 D23

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000014266291
B
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.
C

CL

Revision: November 2016 CL-7 2017 D23

 tom
Symp-
Reference
ble cause)

engage
Clutch slips
Clutch noisy

Clutch does not dis-

Clutch pedal spongy
SUSPECTED PARTS (Possi-

Revision: November 2016

Clutch grabs/chatters
CL-9, "Inspection and Adjustment" CLUTCH PEDAL (Inspection and adjustment)

1
< SYMPTOM DIAGNOSIS >

1
CL-12, "Air Bleeding" CLUTCH LINE (Air in line)

2
2
CL-17, "Exploded View" MASTER CYLINDER PISTON CUP (Damaged)

3
CL-22, "QR25DE : Exploded View" (QR25DE)
CL-25, "YD25DDTi : Exploded View" (YD25DDTi) OPERATING CYLINDER PISTON CUP (Damaged)

4
CL-28, "YS23DDT/YS23DDTT (M9T) : Exploded View" [YS23DDT/YS23DDTT (M9T)]
EM-86, "Exploded View" (QR25DE)
ENGINE MOUNTING (Loose)

1
EM-245, "Exploded View" (YD25DDTi)

CL-36, "GASOLINE ENGINE MODELS : Inspection" (Gasoline engine models)

RELEASE BEARING (Worn, dirty or damaged)

1
CL-39, "DIESEL ENGINE MODELS : Inspection" (Diesel engine models)

CL-8
CLUTCH DISC (Out of true)

5
CLUTCH DISC (Runout is excessive)

5
2
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned)

5
CLUTCH DISC (Oily)

5
2
2
CL-40, "Exploded View" CLUTCH DISC (Worn out)

2
2
CLUTCH DISC (Hardened)

2
CLUTCH DISC (Lack of spline grease)

5
DIAPHRAGM SPRING (Damaged)

6
3
DIAPHRAGM SPRING (Out of tip alignment)

6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion)

7
4
EM-81, "Inspection" (QR25DE) FLYWHEEL (Distortion)

2017 D23
EM-239, "Inspection" (YD25DDTi)
 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000014266292
B

INSPECTION
Clutch Pedal C
1. Make sure that clevis pin (1) floats freely in the bore of clutch
pedal. It should not be bound by clevis or clutch pedal.
CL
2. : Clutch pedal position switch or pedal stopper bolt
3. : Lock nut
a. If clevis pin is not free, make sure that clutch pedal position E
switch or pedal stopper bolt is not applying pressure to clutch
pedal causing clevis pin to bind. To adjust, loosen lock nut and
turn clutch pedal position switch or pedal stopper bolt. F
b. Tighten lock nut. Refer to CL-14, "Exploded View".
JSDIA7210ZZ
c. Make sure that clevis pin floats in the bore of clutch pedal. It
should not be bound by clutch pedal. G
d. If clevis pin is still not free, remove clevis pin and check for deformation or damage. Replace clevis pin if
necessary. Leave clevis pin removed for step 2.
2. Check clutch pedal stroke for free range of movement. H
a. With clevis pin removed, manually move clutch pedal up and down to determine if it moves freely.
b. If any sticking is found, replace related parts (bushing, clutch pedal, etc.). Reassemble clutch pedal and
again make sure that clevis pin floats freely in the bore of clutch pedal. I
3. Check clutch hydraulic and system components (clutch master cylinder, operating cylinder, etc.) for stick-
ing or binding.
a. If any sticking or binding is found, repair or replace related parts as necessary. J
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-12, "Air Bleed-
ing".
NOTE: K
Do not use a vacuum assist or any other type of power bleeder on this system. Use of vacuum assist or
power bleeder will not purge all the air from the system.
Position of Clutch Interlock Switch (With Push-Button Ignition Switch System) L
Check that the clearance (C) between the thread end of clutch inter-
lock switch (1) and stopper rubber (2) is within the specified value
while clutch pedal is fully depressed.
M
Clearance : Refer to CL-43, "Clutch Pedal".
N

O
JPDIB0164ZZ

ADJUSTMENT
P
Position of Clutch Interlock Switch (With Push-Button Ignition Switch System)
1. Disconnect the clutch interlock switch connector.
2. Loosen the clutch interlock switch 45 degrees counterclockwise.

Revision: November 2016 CL-9 2017 D23

 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
3. With the clutch pedal fully depressed, press into the clutch inter-
lock switch (1) until it reaches the stopper rubber (2) and turn the
switch clockwise by 45 degrees to secure it.
CAUTION:
The clearance (C) show in the figure must be within the
specified value.

Clearance : Refer to CL-43, "Clutch Pedal".

NOTE:
Fully depressed clutch pedal means a clutch pedal condition
that the clutch pedal lever contacts the stopper rubber. JPDIB0164ZZ

Revision: November 2016 CL-10 2017 D23

 CLUTCH FLUID
< PERIODIC MAINTENANCE >
CLUTCH FLUID
A
Inspection INFOID:0000000014266293

FLUID LEAKAGE B
• Check clutch tubes and hoses for cracks, deterioration or other damage. Replace any damaged parts.
• Check for fluid leakage by fully depressing clutch pedal while engine is running.
CAUTION: C
If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
FLUID LEVEL
• Check that the fluid level in the reservoir tank is within the specified CL
range (MAX – MIN lines).
• Visually check for any fluid leakage around the reservoir tank.
• Check the clutch system for any leakage if the fluid level is
E
extremely low (lower than MIN).

JPFIA0007ZZ G

Draining INFOID:0000000014266294

H
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. I
1. Connect a transparent vinyl hose to air bleeder valve (1).

JSDIA7438ZZ

M
A. QR25DE models B. YD25DDTi models C. YS23DDT/YS23DDTT (M9T) models

2. Depress clutch pedal and loosen air bleeder valve to gradually discharge clutch fluid.
Refilling INFOID:0000000014266295
N

CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately O
and wash the affected area with water.
• Note the following instructions when filling with clutch fluid:
- Do not use fluid of which performance may be deteriorated because of not storing it in a cool and
dark place with low humidity. P
- The bottle used for filling the reservoir tank with fluid must be free of foreign materials and liquid
other than clutch fluid.
- Check clutch fluid for bubbles and slowly fill with fluid to prevent the generation of bubbles. If bub-
bles are generated, then wait until the bubbles disappear.
- While filling with fluid, do not allow foreign materials to enter into the reservoir tank. If foreign matter
enters into the reservoir tank, then remove them thoroughly with a clean waste or dropper.
1. Connect a transparent vinyl hose to air bleeder valve (1).
Revision: November 2016 CL-11 2017 D23
 CLUTCH FLUID
< PERIODIC MAINTENANCE >

JSDIA7438ZZ

A. QR25DE models B. YD25DDTi models C. YS23DDT/YS23DDTT (M9T)

2. Check that there is no foreign material in reservoir tank and then fill with new clutch fluid.
CAUTION:
• Do not reuse drained clutch fluid.
• Remove foreign materials thoroughly from the reservoir tank, if any, with a clean waste or drop-
per
3. With the air bleeder valve loosened, repeat the following operation at intervals of two to three seconds
until new clutch fluid drains: Fully depress the clutch pedal and release it completely.
4. Depress clutch pedal and loosen air bleeder valve to completely discharge clutch fluid.
5. Repeat step 2 and 3 operations.
CAUTION:
Monitor clutch fluid level in reservoir tank to make sure it does not empty.
6. Tighten air bleeder valve with the clutch pedal depressed.
7. Perform the air bleeding. Refer to CL-12, "Air Bleeding".

Air Bleeding INFOID:0000000014266296

CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• For diesel engine models: Bleed air for clutch connector first, and then for operating cylinder.
• For gasoline engine models: Bleed air for operating cylinder.
• Note the following instructions when filling with clutch fluid:
- Do not use fluid of which performance may be deteriorated because of not storing it in a cool and
dark place with low humidity.
- The bottle used for filling the reservoir tank with fluid must be free of foreign materials and liquid
other than clutch fluid.
- Check clutch fluid for bubbles and slowly fill with fluid to prevent the generation of bubbles. If bub-
bles are generated, then wait until the bubbles disappear.
- While filling with fluid, do not allow foreign materials to enter into the reservoir tank. If foreign matter
enters into the reservoir tank, then remove them thoroughly with a clean waste or dropper.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of vacuum assist or power
bleeder will not purge all the air from the system.
1. Fill reservoir tank with new clutch fluid.
CAUTION:
Do not reuse drained clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve (1).

Revision: November 2016 CL-12 2017 D23

 CLUTCH FLUID
< PERIODIC MAINTENANCE >

JSDIA7438ZZ

CL
A. QR25DE models B. YD25DDTi models C. YS23DDT/YS23DDTT (M9T) models

3. Quickly repeat the following operation five times or more: Fully depress the clutch pedal and release it
completely. After completing this operation, depress the clutch pedal and maintain the condition. E
4. With clutch pedal depressed, loosen air bleeder valve to release air.
5. Tighten air bleeder valve to the specified torque. Refer to CL-22, "QR25DE : Exploded View" (QR25DE),
CL-25, "YD25DDTi : Exploded View" (YD25DDTi), CL-28, "YS23DDT/YS23DDTT (M9T) : Exploded View" F
(YS23DDT/YS23DDTT (M9T)).
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch fluid. G
8. Make sure that clevis pin floats freely in the bore of clutch pedal.
• If clevis pin is not free, perform the air bleeding again to check that bubbles are completely removed.
After the complete removal of bubbles, adjust clutch pedal. H
CAUTION:
When pressing the pedal pad to check the clevis pin condition, press the pedal pad until the devel-
opment of load is felt by hand. I

Revision: November 2016 CL-13 2017 D23

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CLUTCH PEDAL
Exploded View INFOID:0000000014266297

JSDIA7199GB

1. Snap pin 2. Clutch pedal position switch*1*4 3. Pedal stopper bolt*2

4. Pedal pad 5. Clutch pedal assembly 6. Stopper rubber
7. Stopper rubber*3 8. Assist spring 9. Bushing
10. Clevis pin 11. Bushing 12. Clip*3
13. Clutch interlock switch*3 14. Stopper rubber
*1 : With ASCD·
*2 : Without ASCD·(Except YS23DDT/YS23DDTT (M9T Models))
*3 : With push-button ignition switch·
*4 : YS23DDT/YS23DDTT (M9T) Models

Removal and Installation INFOID:0000000014266298

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Remove instrument lower panel. Refer to IP-20, "Removal and Installation".
2. Disconnect clutch pedal position switch harness connector (with ASCD or YS23DDT/YS23DDTT (M9T)
models).
3. Disconnect clutch interlock switch (with push-button ignition switch).

Revision: November 2016 CL-14 2017 D23

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
4. Remove snap pin (1) and clevis pin (2) from clevis of clutch
master cylinder. A

JSDIA5804ZZ

CL
5. Remove the clutch pedal mounting bolt (A).

G
JSDIA5780ZZ

6. Remove the clutch master cylinder mounting nuts (A).

H

JSDIA5782ZZ
K
7. Remove clutch pedal assembly from the vehicle.
8. Remove pedal pad from clutch pedal.
L
9. Remove clutch pedal position switch from clutch pedal (with ASCD or M9T Models).
10. Remove clutch interlock switch and clip from clutch pedal (with push-button ignition switch system).
11. Remove rubber pedal stopper from the clutch pedal, using a suitable tool. M
INSTALLATION
Installation is the reverse order of removal.
N
Inspection and Adjustment INFOID:0000000014266299

INSPECTION AFTER REMOVAL

O
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
• Check pedal stopper rubber. If damage or deformation is found, replace pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad. P
INSPECTION AFTER INSTALLATION
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-9, "Inspection and Adjustment".
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-9, "Inspec-
tion and Adjustment".
ADJUSTMENT AFTER INSTALLATION

Revision: November 2016 CL-15 2017 D23

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-9, "Inspec-
tion and Adjustment".

Revision: November 2016 CL-16 2017 D23

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
A
Exploded View INFOID:0000000014266300

CL

G
JSDIA7426GB

1. Nipple 2. Clamp 3. Hose

4. Cylinder body 5. Dust cover 6. Clevis
H
7. Clevis pin 8. Snap Pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin
I
A. To reservoir tank B. Paint mark

Removal and Installation INFOID:0000000014266301 J

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately K
and wash the affected area with water.
REMOVAL
1. Drain clutch fluid. Refer to CL-11, "Draining". L
2. Disconnect clutch tube (1), using a suitable tool (A). Refer to CL-
33, "Removal and Installation".
M

O
JSDIA5785ZZ

Revision: November 2016 CL-17 2017 D23

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
3. Release hose clamp (2) and remove hose (1) from clutch master
cylinder assembly.

JSDIA6642ZZ

4. Remove snap pin (1) and clevis pin (2).

JSDIA5804ZZ

5. Remove the mounting nuts (A) and the remove clutch master
cylinder assembly (1) from vehicle.

JSDIA5806ZZ

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Apply recommended grease to clevis pin on the mating surface
(A).

JSDIA5807ZZ

Revision: November 2016 CL-18 2017 D23

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
• Check the clevis (1) mounting dimension (L). If measurement is
outside the standard value, adjust the clevis mounting dimension A
to the standard value and tighten lock nut (A) to the specified
torque.
B
Clevis mounting : Refer to CL-43, "Clutch Master
dimension Cylinder".
C

JSDIA3423ZZ

CL
• Tighten clutch tube flare nut to the specified torque.
• Fill clutch fluid. Refer to CL-11, "Refilling".
• Perform inspection after installation. Refer to CL-21, "Inspection". E
Disassembly and Assembly INFOID:0000000014266302

DISASSEMBLY F
1. Remove clevis (1) and lock nut (A).
2. Remove dust cover from cylinder body (2).
G

I
JSDIA3428ZZ

3. Remove stopper ring (1), stopper (2) and push rod (3) from cyl- J
inder body hold it securely to prevent piston assembly popping
out.
CAUTION: K
Restrain the push rod while doing this because there is a
danger the push rod and the piston assembly will fly out of
the cylinder body.
L

JSDIA3430ZZ
M

4. Remove piston assembly (1) and return spring (2) from cylinder
body. N

JSDIA3431ZZ

Revision: November 2016 CL-19 2017 D23

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
5. Remove spring pin from cylinder body, using Tool (A).

Tool number : KV31100300 ( — )

JPDIB0081ZZ

6. Remove nipple (1) and reservoir seal (2) from cylinder body.

JSDIA3427ZZ

ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
• Do not reuse reservoir seal.
• Do not reuse stopper ring.
• Apply rubber lubricant to the internal surface of master cylinder,
the sliding surface and piston cup (A) of piston.

JSDIA5808ZZ

• Apply silicon grease to push rod (A).

JSDIA5809ZZ

Revision: November 2016 CL-20 2017 D23

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
• Adjust the clevis (1) mounting dimension (L) to the standard value
and tighten lock nut (A) to the specified torque. A

Clevis mounting : Refer to CL-43, "Clutch Master

dimension (L) Cylinder". B

JSDIA3423ZZ

CL
Inspection INFOID:0000000014266303

INSPECTION AFTER INSTALLATION E

Check for any of the conditions given below. If any malfunction is found, replace the part concerned.
• Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
• Check for the clutch pedal condition. Refer to CL-9, "Inspection and Adjustment". F
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions given below. If any malfunction is found, replace the part concerned.
• Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole. G
• Damaged or deformed nipple.
• Settling of return spring.
• Cracked or deformed seat. H

Revision: November 2016 CL-21 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
OPERATING CYLINDER
QR25DE
QR25DE : Exploded View INFOID:0000000014266304

JSDIA7216GB

1. Dust cover 2. Push rod 3. Piston assembly

4 Piston spring 5. Cylinder body 6. Air bleeder valve

QR25DE : Removal and Installation INFOID:0000000014266305

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Drain clutch fluid. Refer to CL-11, "Draining".
2. Remove clutch hose from operating cylinder assembly. Refer to CL-33, "Removal and Installation".
3. Remove operating cylinder mounting bolts (A) and then remove
operating cylinder (1) from clutch housing.

JSDIA7217ZZ

INSTALLATION
Installation is in the reverse order of removal.
• Fill clutch fluid. Refer to CL-11, "Refilling".
• Perform inspection after installation. Refer to CL-24, "QR25DE : Inspection".
QR25DE : Disassembly and Assembly INFOID:0000000014266306

DISASSEMBLY

Revision: November 2016 CL-22 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
1. Remove dust cover (1) and push rod (2).
A

JSDIA3449ZZ

CL
2. Remove piston assembly (1) and piston spring (2) from cylinder
body.
E

G
JSDIA3450ZZ

3. Remove air bleeder valve (1).

H

JSDIA3451ZZ
K
ASSEMBLY
Assembly is in the reverse order of disassembly.
• Apply rubber lubricant to the internal surface of cylinder body. L

JSDIA3452ZZ O

Revision: November 2016 CL-23 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
• Apply rubber grease to the sliding surface of piston and piston cup.

JSDIA3453ZZ

• Apply silicone grease to the piston assembly contact surface of

push rod.

: Piston assembly side

JSDIA3454ZZ

• Apply rubber grease into the dust cover.

JSDIA3455ZZ

QR25DE : Inspection INFOID:0000000014266307

INSPECTION AFTER INSTALLATION

Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions given below. If any malfunction is found, replace the part concerned.
• Damage to cylinder inner surface or piston sliding surface, foreign matter, wear, corrosion, or pinhole.
• Settling of piston spring.
• Cracked or deformed dust cover.
YD25DDTi

Revision: November 2016 CL-24 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
YD25DDTi : Exploded View INFOID:0000000014266308

CL

JSDIA7218GB
F
1. Dust cover 2. Push rod 3. Piston assembly
4 Piston spring 5. Cylinder body 6. Air bleeder valve
G
YD25DDTi : Removal and Installation INFOID:0000000014266309

CAUTION: H
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL I
1. Drain clutch fluid. Refer to CL-11, "Draining".
2. Remove clutch hose from operating cylinder assembly. Refer to CL-33, "Removal and Installation".
J
3. Remove operating cylinder mounting bolts (A) and then remove
operating cylinder (1) from clutch housing.

M
JSDIA3456ZZ

INSTALLATION
Installation is in the reverse order of removal. N
• Fill clutch fluid. Refer to CL-11, "Refilling".
• Perform inspection after installation. Refer to CL-27, "YD25DDTi : Inspection".
YD25DDTi : Disassembly and Assembly INFOID:0000000014266310 O

DISASSEMBLY
P

Revision: November 2016 CL-25 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
1. Remove dust cover (1) and push rod (2).

JSDIA3987ZZ

2. Remove piston assembly (1) and piston spring (2) from cylinder
body.

JSDIA3458ZZ

3. Remove air bleeder valve (1).

JSDIA3459ZZ

ASSEMBLY
Assembly is in the reverse order of disassembly.
• Apply rubber lubricant (A) to the internal surface of cylinder body.

JSDIA5812ZZ

Revision: November 2016 CL-26 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
• Apply rubber grease (A) to the sliding surface of piston and piston
cup. A

JSDIA5811ZZ

CL
• Apply silicone grease (A) to the piston assembly contact surface of
push rod.
E
: Piston assembly side

G
JSDIA5813ZZ

• Apply rubber grease (A) into the dust cover. H

JSDIA5814ZZ
K

YD25DDTi : Inspection INFOID:0000000014266311

L
INSPECTION AFTER INSTALLATION
Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
INSPECTION AFTER DISASSEMBLY M
Check for any of the conditions given below. If any malfunction is found, replace the part concerned.
• Damage to cylinder inner surface or piston sliding surface, foreign matter, wear, corrosion, or pinhole.
• Settling of piston spring. N
• Cracked or deformed dust cover.
YS23DDT/YS23DDTT (M9T)
O

Revision: November 2016 CL-27 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
YS23DDT/YS23DDTT (M9T) : Exploded View INFOID:0000000014266312

JSDIA7433GB

1. Dust cover 2. Push rod 3. Piston assembly

4. Piston spring 5. Cylinder body 6. Air bleeder valve

YS23DDT/YS23DDTT (M9T) : Removal and Installation INFOID:0000000014266313

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Drain clutch fluid. Refer to CL-11, "Draining".
2. Remove clutch hose from operating cylinder assembly. Refer to CL-33, "Removal and Installation".
3. Remove operating cylinder mounting bolts (A) and then remove
operating cylinder (1) from clutch housing.

JSDIA7434ZZ

INSTALLATION
Installation is in the reverse order of removal.
• Fill clutch fluid. Refer to CL-11, "Refilling".
• Perform inspection after installation. Refer to CL-11, "Inspection".
YS23DDT/YS23DDTT (M9T) : Disassembly and Assembly INFOID:0000000014266314

DISASSEMBLY

Revision: November 2016 CL-28 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
1. Remove dust cover (1) and push rod (2).
A

JSDIA7435ZZ

CL
2. Remove piston assembly (1) and piston spring (2) from cylinder
body.
E

G
JSDIA7436ZZ

3. Remove air bleeder valve (1).

H

JSDIA7437ZZ
K
ASSEMBLY
Assembly is in the reverse order of disassembly.
• Apply rubber lubricant to the internal surface of cylinder body. L

JSDIA3460ZZ O

Revision: November 2016 CL-29 2017 D23

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
• Apply rubber grease to the sliding surface of piston and piston cup.

JSDIA3453ZZ

• Apply silicone grease to the piston assembly contact surface of

push rod.

: Piston assembly side

JSDIA3461ZZ

• Apply rubber grease into the dust cover.

JSDIA3455ZZ

YS23DDT/YS23DDTT (M9T) : Inspection INFOID:0000000014266315

INSPECTION AFTER INSTALLATION

Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions given below. If any malfunction is found, replace the part concerned.
• Damage to cylinder inner surface or piston sliding surface, foreign matter, wear, corrosion, or pinhole.
• Settling of piston spring.
• Cracked or deformed dust cover.

Revision: November 2016 CL-30 2017 D23

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
A
Exploded View INFOID:0000000014266316

QR25DE MODELS B

CL

G
ALDIA0598ZZ

1. Clutch master cylinder assembly 2. Clutch tube 3. Bracket

H
4. Clutch hose 5. Lock plate 6. Copper washer
7. Operating cylinder assembly

YD25DDTi MODELS I

AWDIA1293ZZ

Revision: November 2016 CL-31 2017 D23

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >

1. Clutch tube A 2. Clutch orifice 3. Connector

4. Clutch tube B 5. Bracket 6. Clutch tube C
7. Bracket 8. Lock plate 9. Clutch hose
10. Clip 11. Copper washer 12. Operating cylinder assembly
13. Bleeder cap 14. Bleeder screw 15. Connector
16. Clutch tube D 17. Clutch master cylinder assembly
:Indicates that the part is connected at points with same symbol in actual vehicle.
:Indicates that the part is connected at points with same symbol in actual vehicle.

YS23DDT/YS23DDTT (M9T) MODELS

AWDIA1294ZZ

1. Clutch tube A 2. Clutch orifice 3. Connector

4. Clutch tube B 5. Bracket 6. Clutch tube C
7. Bracket 8. Lock plate 9. Clutch hose
10. Clutch tube D 11. Operating cylinder assembly 12. Copper washer
13. Clutch master cylinder assembly 14. Bleeder screw 15. Bleeder cap
16. Connector

Hydraulic Layout INFOID:0000000014266317

GASOLINE ENGINE MODELS

Revision: November 2016 CL-32 2017 D23

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >

JSDIA7207ZZ

CL
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder assembly 5. Operating master cylinder assembly 6. Clutch pedal

E
DIESEL ENGINE MODELS

JSDIA6645ZZ

1. Clutch tube A 2. Clutch orifice 3. Clutch tube B

I
4. Connector 5. Clutch tube C 6. Lock plate
7. Clutch hose 8. Operating cylinder assembly 9. Clutch tube D
J
10. Connector 11. Bleeder screw 12. Clutch master cylinder assembly
13. Clutch pedal

Removal and Installation INFOID:0000000014266318 K

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately L
and wash the affected area with water.
REMOVAL
NOTE: M
Remove clutch tube using a flare nut wrench.
CAUTION:
Do not damage flare nut and clutch tube.
N
1. Drain clutch fluid. Refer to CL-11, "Draining".
2. Remove Brake booster. Refer to BR-40, "Removal and installation".
3. Remove Clutch master cylinder. Refer to CL-17, "Removal and Installation". O
4. Remove Clutch tube A from Clutch orifice and remove Clutch tube A.
5. Remove Clutch tube B from clutch orifice.
6. Remove Clutch tube B from Connector and remove clutch tube B. P
7. Remove clutch tube D from Clutch orifice.
8. Remove clutch tube D from Connector and remove Clutch tube D.
9. Remove Clutch tube C from Clutch orifice.
10. Remove Clutch hose C from Bracket.
11. Remove Lock plate from Clutch hose.
12. Remove screw and remove Clutch hose from Operating cylinder assembly.
Revision: November 2016 CL-33 2017 D23
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Do not reuse copper washer.
• To fix clutch hose on bracket (1), position clutch hose clasp on the
emboss (2) of bracket and drive lock plate (3).
CAUTION:
• Do not bend or twist clutch hose.
• Do not scratch or damage clutch hose.
• When installing clutch hose to operating cylinder assembly, insert
clutch hose protrusion into operating cylinder hole. (M9T Models).
CAUTION:
• Do not bend or twist clutch hose.
• Do not scratch or damage clutch hose.
• Tighten clutch hose flare nut to the specified torque. Refer to CL-
JSDIA6641ZZ
31, "Exploded View"
• Fill clutch fluid. Refer to CL-11, "Refilling".
• Perform inspection after installation. Refer to CL-34, "Inspection".
Inspection INFOID:0000000014266319

INSPECTION AFTER REMOVAL

Check the clutch tube for cracks and damage. If the clutch tube has cracks or damage, replace it with a new
one.
INSPECTION AFTER INSTALLATION
Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".

Revision: November 2016 CL-34 2017 D23

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
CLUTCH RELEASE MECHANISM
A
GASOLINE ENGINE MODELS
GASOLINE ENGINE MODELS : Exploded View INFOID:0000000014266320
B
QR25DE MODELS

CL

JSDIA7266ZZ

H
1. Retainer spring 2. Withdrawal lever 3. Dust cover
4. Release bearing 5. Release bearing sleeve 6. Holder spring
I
GASOLINE ENGINE MODELS : Removal and Installation INFOID:0000000014266321

REMOVAL
J
1. Remove transmission assembly from the vehicle. Refer to TM-30, "2WD : Removal and Installation".
2. Remove withdrawal lever (1) and release bearing assembly (2)
from transmission assembly. K
3. Remove dust cover from transmission assembly.
4. Remove holder spring from withdrawal lever and release bear-
ing sleeve. L
5. Remove retainer spring from withdrawal lever.

JSDIA3491ZZ

N
6. Remove release bearing from release bearing sleeve using a
suitable tool.

CLA0013D

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Revision: November 2016 CL-35 2017 D23
 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
• If grease is not applied, noise, wear, and damage of clutch may occur. Always apply the grease. If an
excessive amount of grease is applied, it may cause slip and judder. Wipe off any grease oozing
from the parts.
• Keep the facing of clutch disc, pressure plate surface, and flywheel surface free of grease.
• Wipe off old grease and wear particles, etc. that are on the grease applied parts.
• Install release bearing (1) to release bearing sleeve (2) using Tool
(A).

Tool number : KV30101400 ( — )

CAUTION:
Press bearing inner part by pushing with the drift.

JSDIA3994ZZ

• Apply recommended grease to the area indicated in the figure. For

recommended grease, refer to CL-35, "GASOLINE ENGINE MOD-
ELS : Exploded View".
- Apply recommended grease [thickness: approximately 1 mm (0.04
in)] evenly to the sliding surface (A) of the withdrawal lever and the
sliding surface (B) of the release bearing sleeve.
- Apply recommended grease entirely covering the ball pin contact
surface (C) of the withdrawal lever and the groove (D) of the
release bearing inner surface.
- Evenly and lightly apply recommended grease to the sliding sur-
face (E) of front cover. Insert release bearing sleeve to front cover.
Pull out the release bearing sleeve and wipe out excess grease.
• Operate the withdrawal lever before installing the transmission
assembly to the vehicle. Check that each sliding surface moves
smoothly.

JPDIB0095ZZ

GASOLINE ENGINE MODELS : Inspection INFOID:0000000014266322

INSPECTION AFTER REMOVAL

• Check the release bearing for seizure, damage, unsmooth rotation.
If any malfunction is found, replace release bearing.
• Check the contact surface of withdrawal lever for excessive wear.
If any malfunction is found, replace withdrawal lever.
• Check the dust cover for cracks and deformation. If found, replace
dust cover.

JSDIA7440ZZ

DIESEL ENGINE MODELS

Revision: November 2016 CL-36 2017 D23

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
DIESEL ENGINE MODELS : Exploded View INFOID:0000000014266323

CL

JSDIA6873ZZ

G
1. Snap ring 2. Withdrawal lever 3. Dust cover
4. Release bearing 5. Release bearing sleeve 6. Holder spring

DIESEL ENGINE MODELS : Removal and Installation INFOID:0000000014266324

H

REMOVAL
1. Remove transmission assembly from the vehicle. Refer to TM-30, "2WD : Removal and Installation" I
(2WD) and TM-35, "4WD : Removal and Installation" (4WD).
2. Remove withdrawal lever (1) and release bearing assembly (2)
from transmission assembly. J

JSDIA3522ZZ
M
3. Remove dust cover (1).

P
JSDIA3523ZZ

Revision: November 2016 CL-37 2017 D23

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
4. Remove withdrawal lever from holder spring (1) with sleeve and
bearing.
5. Remove snap spring from withdrawal lever.

JPDIB0198ZZ

6. Remove release bearing from release bearing sleeve using a

suitable tool.

CLA0013D

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• If grease is not applied, noise, wear, and damage of clutch may occur. Always apply the grease. If an
excessive amount of grease is applied, it may cause slip and judder. Wipe off any grease oozing
from the parts.
• Keep the facing of clutch disc, pressure plate surface, and flywheel surface free of grease.
• Wipe off old grease and wear particles, etc. that are on the grease applied parts.
• Install dust cover (1) to clutch housing as shown in the figure.

: Front

JSDIA3411ZZ

• Install release bearing (1) to release bearing sleeve (2) using Tool
(A).

Tool number : KV30101400 ( — )

CAUTION:
Press bearing inner part by pushing with the Tool.

JSDIA3994ZZ

Revision: November 2016 CL-38 2017 D23

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
• Install snap ring to withdrawal lever as shown.
CAUTION: A
• When assembling, check that both ends of snap spring
touch the end face of withdrawal lever (2).
• Be careful with the orientation of snap spring (1).
B

JSDIA5816ZZ

CL
• Apply recommended grease to the area indicated in the figure. For
recommended grease, refer to CL-37, "DIESEL ENGINE MODELS
: Exploded View". E
- Apply recommended grease thickness: approximately 1 mm (0.04
in) evenly to the sliding surface (A) of the withdrawal lever and the
sliding surface (B) of the release bearing sleeve.
- Apply recommended grease entirely covering the ball pin contact F
surface (C) of the withdrawal lever and the groove (D) of the
release bearing inner surface.
- Evenly and lightly apply recommended grease to the sliding sur- G
face (E) of front cover. Insert release bearing sleeve to front cover.
Pull out the release bearing sleeve and wipe out excess grease.
• Operate the withdrawal lever before installing the transmission H
assembly to the vehicle. Check that each sliding surface moves
smoothly.

JSDIA3410ZZ
K
DIESEL ENGINE MODELS : Inspection INFOID:0000000014266325

INSPECTION AFTER REMOVAL L

• Check the release bearing for seizure, damage, unsmooth rotation.
If any malfunction is found, replace release bearing.
• Check the contact surface of withdrawal lever for excessive wear. M
If any malfunction is found, replace withdrawal lever.
• Check the dust cover for cracks and deformation. If found, replace
dust cover.
N

O
JSDIA7440ZZ

Revision: November 2016 CL-39 2017 D23

 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
Exploded View INFOID:0000000014266326

AWDIA1295ZZ

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Main drive gear
A. Refer to INSTALLATION

Removal and Installation INFOID:0000000014266327

CAUTION:
• Do not bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Do not clean clutch disc using solvent.
REMOVAL
1. Remove transmission assembly. Refer to TM-30, "2WD : Removal and Installation" (2WD) and TM-35,
"4WD : Removal and Installation" (4WD).
2. Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Do not drop clutch disc.
3. Remove clutch cover and clutch disc
CAUTION:
Do not drop clutch disc.
INSTALLATION
1. Clean clutch disc and main drive gear splines (A) to remove
grease and powder arisen from abrasion.

: Engine side

2. Apply recommended grease to clutch disc and main drive gear

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 judder. Wipe off
JSDIA3357ZZ
any grease oozing from the parts.

Revision: November 2016 CL-40 2017 D23

 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
3. Install clutch disc, using a suitable tool (A) and temporarily install
clutch cover. A
CAUTION:
• Do not drop clutch disc and clutch cover.
B

JSDIA3358ZZ

CL
• Be careful with the orientation of the clutch disc.

: Engine side E

G
JSDIA7442ZZ

4. Tighten clutch cover mounting bolts in order from 1 to 8 in two H

steps as shown.

Step one : 14.7 N·m (1.5 kg-m, 11 ft-lb)

I
Step two : 25 N·m (2.6 kg-m, 19 ft-lb)

PCIB1772E K
5. Install transmission assembly to the vehicle. Refer to TM-30, "2WD : Removal and Installation" (2WD) and
TM-35, "4WD : Removal and Installation" (4WD).
L
Inspection INFOID:0000000014266328

INSPECTION AFTER REMOVAL M

Clutch Disc
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. N

Runout limit/diameter of the area to : Refer to CL-43,

be measured "Clutch Disc".
O
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc.
P
Maximum allowable spline back- : Refer to CL-43,
SCL221
lash (At outer edge of disc) "Clutch Disc".

Revision: November 2016 CL-41 2017 D23

 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
• Measure the depth (A) to clutch disc facing rivet heads using a cal-
ipers. If it exceeds the allowable wear limit, replace clutch disc.

Facing wear limit (Depth to the rivet : Refer to CL-43,

head) "Clutch Disc".

JPDIB0026ZZ

Clutch cover
• Check clutch cover thrust rings for wear or breakage. If wear or breakage is found, replace clutch cover.
NOTE:
• A worn thrust ring causes beating noise when the rivet is tapped with a hammer.
• A broken thrust ring causes clinks when the cover is shaken vertically.
• 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 clutch cover.
INSPECTION AFTER INSTALLATION
CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using Tool (A).

Tool number : ST20050240 ( — )

Tolerance for diaphragm spring le- : Refer to CL-44,

ver unevenness "Clutch Cover".

JPDIB0160ZZ

Revision: November 2016 CL-42 2017 D23

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000014266329
B
Unit: mm (in)

YS23DDT/YS23DDTT C
Engine type QR25DE YD25DDTi
(M9T)
Type of clutch control Hydraulic
Clutch mas- CL
Cylinder inner diameter 15.87 (5/8)
ter cylinder
Operating
Cylinder inner diameter 19.05 (3/4)
cylinder
E
Facing size 240 × 160 × 3.5 275 × 180 × 3.2
Clutch disc
(Outer dia. × Inner dia. × Thickness) (9.45 × 6.30 × 0.138) (10.83 × 7.09 × 0.126)
Recommended clutch fluid Refer to MA-23, "Fluids and Lubricants". F
Clutch Pedal INFOID:0000000014266330

Unit: mm (in) G
Item Standard
Clearance “C” between stopper rubber and clutch interlock switch
2.2 – 3.2 (0.087 – 0.126) H
threaded while clutch pedal is fully depressed.

Clutch Master Cylinder INFOID:0000000014266331

I
Unit: mm (in)

Item Standard
Clevis mounting dimension (L) J

120.5 – 121.5 (4.74 – 4.78) K

PCIB1944E L

Clutch Disc INFOID:0000000014266332

Unit: mm (in) M
Item Standard
QR25DE 1.0 (0.039) / 230 (9.06) dia.
N
YD25DDTi
Runout limit/diameter of the area to be measured
YS23DDT/YS23DDTT 0.7 (0.028) / 265 (10.43) dia.
(M9T) O
QR25DE
YD25DDTi
Maximum allowable spline backlash (at outer edge of disc) 1.0 (0.039)
YS23DDT/YS23DDTT P
(M9T)
QR25DE
YD25DDTi
Facing wear limit (depth to the rivet head) 0.3 (0.012)
YS23DDT/YS23DDTT
(M9T)

Revision: November 2016 CL-43 2017 D23

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Cover INFOID:0000000014266333

Unit: mm (in)

Item Standard
QR25DE 0.7 (0.028) or less
YD25DDTi
Tolerance for diaphragm spring lever unevenness
YS23DDT/YS23DDTT 1.0 (0.039) or less
(M9T)

Revision: November 2016 CL-44 2017 D23