Question about 1990 Nissan Pulsar

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How to replace a cluch

I need to replace my cluch on my nissan pulsar vector i have never done it before so i need a step by step instructions can any one help me also is a DIY job & what parts do i need to buy

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  • Kirk Augustin
    Kirk Augustin May 11, 2010

    You sure the clutch is slipping from being worn thin and it is not just that the linkage is too tight? If you are sure it is the clutch, then you need to either take out the engine or the transmission, because the clutch is between them. The transmission is usually easier. But it has a speedometer cable, shift linkage, and axels. Then there are basically a ring of bolts between engine and transmission. Finally, you need to support the transmission on a rolling jack below, or a sling from above, as you pull it about 4 inches back, so that the tranmission shaft will come out of the clutch. The clutch is a thin disk with a splined hub that fits onto the trans shaft. The disk is pinched between the engine flywheel, and the clutch pressure plate, which is bolted to the flywheel. Once the transmission is back, it is easy to unbold the pressure plate and replace the disk. They sell a plastic shaft that simulates the trransmission shaft, so that you can hold the new disk in place, while you rebolt the plate over it.

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You will need:
1.) A repair manual or the procedures off of http://www.alldatadiy.com or Mitchell at http://www.eautorepair.com
2.) A full toolbox of prybars, screwdirvers, proper metric wrenches and metric sockets (Deep well and shallow in 10,11,12,12,14,15,17,18 & 19mm ), a spindle nut socket set or a 30, 32, 34, 36mm set of impact sockets, and some tie downs or good small bungee cords to tie the struts out of the way,etc.
3.) Fluids: New brake fluid to bleed the brakes after loosening the calipers for removal, New transmission fluid (generally 5w or 10w-30 is the proper gear oil for smaller Japanese imports of that vintage), and coolant if you have to remove the hoses, which I think you will in order to gain full access to the transmission case for removal.
4.) Use the repair guide as your DIY bible, but basically, you'll disconnect the battery,starter, and harnesses to trans, then you'll have to remove the calipers, axles (this is where the prybar comes in handy) and move the struts out to the side or remove completely, remove radiator hoses and clutch cable, trans mounts, etc to gain total access to transmission. I also believe you will have to remove one of the rotating parts above as well as the air intake to gain access to the portion of the bell housing above. Use the repair guide for the rest.
5.) DO NOT resintall the clutch until you have had the flywheel resurfaced and the pilot shaft bushing replaced. make sure you get a good kit, like a Sachs or Exedy, no cheapy CSK or NAPA clutches for your Nissan, you'll thank me later. Also make sure you get a kit with an alignment tool, throwout bearing, new pressure plate and clutch disc. You want to pay the xtra money for the better kits, so get one from Motion/Federated Auto or from Carquest ro the Nissan Dealer.
6.) Most important rule: take your time!!! Do not get in a hurry trying to remove bolts or removing the transmission. If this is your first time, follow the steps listed and take whatever time you'll need. Plan on 5-8 hours for your 1st clutch job, and Nissans are a great 1st one because the transmissions are light and the clutches are very forgiving and easy to change.
7.) Upon reinstall, make sure to follow directions on the torque procedure for the flywheel and the clutch plate. This is critical for a Nissan. Also, when you reinstall the axles, make sure the break in the inner circlip (retaining clip attached to the inner axle splines) is facing down and not up, otherwise you'll never get the axles back in. Trust me, it's much easier this way.
8.) have fun and happy clutching. If you get stuck, email back and I'll see if I can help.

Kevin
Spokane, WA

Posted on Sep 12, 2009

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I could talk you through this step by step, but it is much better to have pictures too. You can get a HAYNES REPAIR MANUAL for less than $20 at your local auto parts store. This will help you alot, but make sure you have the proper equipment: a good floor jack, jack stands. You will be taking the transmission out of the car, so the car will have to be on jacks securely.
You don't necessarily need to buy all this, because you can rent them.
Purchase a repair manual. After studying it, you'll need to buy a clutch plate, pressure plate and throw-out bearing and a new pilot bushing if so equipped.
You can also ask about an "alignment tool" for putting the plates together correctly...
do your homework and get well-prepared... it's much more involved than we could give you hear... A repair manual with pictures and step by step will make a whole lot easier for you...
Go get em!
k

Posted on Sep 12, 2009

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