ZeroProd

Whats going on people. I have just purchased a 1990 240sx se and am going to need to replace the clutch very soon. I was wondering what all is involved in this process like how long would it take to change, what i need to do it, and if i should try and do it myself. Thanks

crxnfx

well help us out and tell us your car knowledge. Do you know what a socket wrench is? Torque wrench? Lefty Loosey righty tighty?

If its your first major mod or work with a car, I would ask for some help. Swapping clutches is fairly easy. Go to Autozone and get a book for your car. That will at least get you started.

ZeroProd

i have turned wrenches on my car before i dont have any professional training but i can figure out pretty much anything i get into. Once i get my tax return i plan on buying the factory service manual. Is there anything else i should replace besides what is included in most clutch kits?

patrck

You're probably going to want to replace or at least resurface your flywheel.

cantseemyfeet

Make sure the Clutch Kit has ALL the goodies (throw-out bearing, alignment tool, etc) or you will be a very pissed off dude when you get half way through your project.

M1KeyC

Im actually about to do the same thing to my 90 240

WarriorBlaZe

Parts:

Clutch kit (disc, pressure plate, throw out bearing, pilot bearing/bushing) I'd stay away from a stock replacement, go ahead and spring for a nice ACT or SPEC stage 2 or 3. You'll be glad you did later.
Resurfaced stock flywheel or lightweight replacement
3 qts of 75-90w gear oil (I like Redline)
A few cans of brake cleaner

Tools:
Metric combination wrenches
Metric socket set (3/8" and 1/2")
Ratchets
Torque wrench
Various lengths of extensions (long ones come in very handy)
Universal Joints (I like the impact universals because they don't flop around)
Drain pan

I can't give you a complete break down of the clutch job. There are alot of articles out there about it. Search 240sxforums.com for a better write up.

Jack the car up as high as possible and support with jack stands

Disconnect the battery

Remove the starter

Mark drive shaft for correct orientation

Remove the drive shaft: 4 bolts at the pinion flange (14mm be sure to have a 12 point wrench) and the 2 bolts holding the carrier bearing. After the pinion flange and carrier bearing are loose the drive shaft can be removed by pulling it straight back. Have the drain pan ready, as the gear oil will start flowing out of the tailshaft

Remove clutch slave cylinder and tie up out of the way

Remove the Shifter handle

Remove the plastic console trim

Remove the rubber shifter boot

Remove the shifter 6 12mm bolts hold this in, the 4 around the shifter are easy. The front 2 bolts can be tricky, just be patient with a combination wrench and they'll come out. Pull straight up on the shifter to remove the assembly, don't lose the spring under the assembly

Remove the transmission crossmember

Remove the bell housing bolts

Slide the transmission back off the dowel pins This may take some wiggling

Rotate the transmission 180 degrees (upside down) This is the only way the bell housing will clear the trans tunnel due to the starter boss

Jack up the engine using a board under the oil pan

Slide the transmission back and out

Place clutch tool into the old clutch assembly

Remove pressure plate bolts

Remove clutch assembly

Remove flywheel bolts You may need to use a pry bar against the teeth to hold it still

Replace pilot bearing I usually break the old one into small pieces with a chisel and then blow it out with compressed air. Install the new one by tapping it in w/a hammer and socket. Be careful not to break it.

Replace throw out bearing

Clean clutch particles from inside of bell housing

Resurface or replace flywheel

Torque flywheel bolts to 110ft/lbs

Clean flywheel with brake cleaner

Clean clutch disc and pressure plate with brake cleaner

Place clutch disc on flywheel w/alignment tool Make sure to put the engine side against the flywheel or vice versa. It should be marked

Install pressure plate over clutch disc and alignment tool

Torque pressure plate bolts to 20ft/lbs

Remove alignment tool

Installation is reverse of removal

This should get you started. A transmission jack and a helper are good to have. The trans isn't SUPER heavy, but you won't want it laying on your chest. Allow the clutch to break in for about 500 miles before beating on it.

Hope this helps, good luck.

ZeroProd

Thanks all for the input. Thanks WarriorBlaZe for the write up.

drifterJERRY

i would like to add one step that helps out drastically when trying to get to the top bellhousing bolts on the overly-tall nissan bellhousings. There are 4 bolts that hold the front crossmember. I beleive they are 19mm. Loosen them to the last few threads, thus dropping the engine and tranny an inch or so, and this will help very much when getting to the top tranny bolts. good luck.

ZeroProd

Thanks again everyone for the assistance.