clutch pressure plate 30210- 4JA0A,30210-4JA0B,Clutch plate 301004JA0A， 30210-4JA0A，30100-4JA0A YD25， NP300，0210-4JA0B、302104JA0B FOR Nissan Navara

I. Preparation and Core Tools

1. Safety Confirmation:

• Ensure the vehicle is lifted securely, the transmission has been removed, and the negative battery terminal is disconnected.

2. Navara-Specific Tools:

• Clutch Aligning Tool: Mandatory. The Navara's input shaft is long; improper alignment will prevent the transmission from being reinstalled.

• Torque Wrench: Requires two ranges: 20-60 N·m and 60-120 N·m.

• Specialized Grease: High-temperature grease (usually included with the clutch kit).

II. Critical Step: Confirm Installation Direction (Navara-Specific Markings)

1. Check Markings:

• The side stamped with "FRONT" or "FLYWHEEL SIDE" faces the engine (flywheel).

• The side stamped with "REAR", "T/M SIDE", or "TRANSMISSION" faces the transmission.

2. Check Hub:

• If markings are unclear, observe the spline hub. The side with the longer hub (more protruding side) faces the transmission.

• Caution: If installed backwards, the transmission input shaft will bottom out against the crankshaft, preventing the transmission from being pushed fully into place.

III. Installation Steps (Standard Procedure)

1. Flywheel and Pilot Bearing Inspection (Navara Focus)

• Clean Flywheel: Use fine sandpaper to polish minor glazing or grooves on the flywheel surface, and clean thoroughly with anhydrous alcohol to remove oil.

• Inspect Pilot Bearing: Insert a screwdriver into the pilot bearing at the center of the crankshaft and check if it rotates smoothly.

• Navara Common Issue: This bearing is prone to wear and seizure. It is recommended to replace it directly; otherwise, it will cause judder during take-off.

2. Lubrication Process

• Friction Disc Splines: Apply a small amount of high-temperature grease (a thin layer) to the internal splines of the friction disc.

• Warning: Strictly prohibit grease from contaminating the friction surfaces (the linings), as this will definitely cause slippage.

• Input Shaft (Transmission Side): If reinstalling the transmission, be sure to also apply grease to the transmission input shaft splines.

3. Install Pressure Plate and Friction Disc

• Install Pressure Plate (Clutch Cover):

• Place the pressure plate on the flywheel and align it with the locating dowels.

• Hand-thread the 6 mounting bolts; do not tighten yet, allowing the pressure plate to move slightly.

• Install Friction Disc (Clutch Disc):

• Place the friction disc in the center of the pressure plate.

• Insert Aligning Tool: Pass the tool through the friction disc and into the crankshaft pilot bearing.

• Adjust Alignment: Move the friction disc up, down, left, and right until the aligning tool can rotate 360 degrees very smoothly. This is the key to successful installation.

4. Tighten Pressure Plate Bolts (Core Torque)

• Sequence: Must be tightened in three passes following a diagonal crisscross sequence (Star Pattern).

• Navara Standard Torque:

• Typically 22 N·m - 25 N·m (Refer to the vehicle nameplate or service manual for specifics. Do not use excessive force, as this will deform the pressure plate and cause judder).

• Check: After tightening, confirm once again that the aligning tool rotates smoothly, then remove the tool.

5. Install Release Bearing

• For the D40 Navara, the release bearing is typically installed on the transmission input shaft.

• Apply Grease: Apply specialized grease to the inner ring of the release bearing and the contact point between the release fork and the bearing.

• Ensure the bearing retaining clip is installed securely.

I. Orientation and Structural Confirmation (Navara-Specific Risks)

• Action: Must be confirmed repeatedly before installation. Navara friction discs usually have clear markings: "T/M SIDE" (Transmission side) or "FLYWHEEL SIDE" (Engine side).

• Structural Feature: If no markings are present, the side with the longer (protruding) spline hub must face the transmission.

• Consequence: The Navara's transmission input shaft is long. If installed backwards, the input shaft will bottom out against the crankshaft rear oil seal or pilot bearing seat, preventing the transmission from seating. Forcing it will crush the friction disc or damage the crankshaft.

• Navara Common Issue: DMF failure is common in diesel Navaras.

• Inspection: If there is a "clunking" metal impact sound during take-off, or if excessive backlash (play) is detected between the two flywheel masses, the flywheel must be replaced.

• Consequence: Replacing only the clutch disc without replacing a failed flywheel will result in severe judder during take-off and a drastically shortened lifespan for the new disc.

II. Lubrication and Cleaning (Core Lifespan Factors)

• Action: Apply high-melting point grease (usually included with the clutch kit) to the friction disc spline hub and the transmission input shaft splines.

• Navara Focus: The Navara's high torque places significant stress on the splines. Lubrication is mandatory; otherwise, splines will wear rapidly or corrode, causing poor clutch pedal return or difficulty shifting.

• Taboo: Strictly prohibit grease from spilling onto the friction surfaces (linings), as this will definitely cause slippage and burnout.

• Action: Located at the center of the crankshaft.

• Recommendation: Strongly recommend replacing it directly. Navaras typically accumulate high mileage, and this bearing is prone to seizure due to lack of lubrication.

• Consequence: A seized bearing will cause wear to the front of the input shaft, leading to clutch judder and abnormal noise.

References：

I. Core Official Authoritative Sources (Primary Basis)

• Manual Name: Nissan Navara D40/D23 Series Service Manual

• Section Location: Section CL (Clutch), specifically the sub-chapter "Clutch Disc and Clutch Cover Installation."

• Core Content: Specifications for friction disc orientation markings (T/M SIDE / FLYWHEEL SIDE), diagonal/crisscross tightening sequence for pressure plate bolts, standard torque (22–25 N·m), mandatory requirement for the aligning tool, spline lubrication standards, and Dual Mass Flywheel (DMF) inspection criteria.

• Technical Parameters Source: Service Data & Specifications (SDS) - YD25DDTi Engine Specific Parameter Table (including pressure plate bolt torque and pilot bearing replacement standards).

• Manual Number Examples:

• Navara D40 (2005–2015): Nissan Navara D40 Service Manual – Section CL.

• Navara D23 (NP300, 2014–Present): Nissan Navara D23 (NP300) Service Manual – Section CL.

• Scope: Special revised guidelines for common clutch faults in Navara YD25 engines (e.g., DMF noise, judder caused by pressure plate deformation).

• Example Numbers: TSB CL-001 (YD25DDTi Clutch Installation Torque Correction), TSB CL-005 (DMF Wear Judgment Standard).

• Location: Stamped markings on the transmission housing and bell housing. These explicitly indicate friction disc direction, pressure plate dowel positions, and bolt tightening sequences, serving as direct authoritative references for on-site installation.

II. Component Supplier Technical Specifications (Component-Level Basis)

• Navara Major Suppliers: NSK, Aisin, Schaeffler (LuK).

• Core Requirements: Specifications for the amount of grease for friction disc splines, oil contamination prevention standards for friction surfaces, maintenance-free/replacement standards for release bearings, and DMF detection parameters. These are fully consistent with the Nissan official manual.

• Reference Documents: Schaeffler REPXPERT Navara Clutch Installation Guide, Aisin Clutch Kit Service Manual (Suitable for YD25 engine).

III. Industry General Standards and Supplementary References (Compliance Basis)

• Standard Number: JASO C 404 (Automotive Clutch Facing Tester). Specifies general technical standards for clutch installation environment cleanliness, friction disc balance requirements, and installation tolerances.

• Standard Number: Automotive repair quality management system under ISO 9001. Covers process control, torque management, and error-proofing requirements for clutch installation.

• Platforms: Chilton, Haynes, AutoManuals.biz. These compile practical precautions based on Nissan factory manuals, suitable for troubleshooting scenarios, and their content is consistent with official manuals.