Clutch replacement on 93 Nissan Truck - D21 with a SAS
 This is how I changed my Clutch, Pressure plate and throw out bearing on a 1993 4wd. Other Nissans similar.

Tools needed. Numerous sockets and wrenchs, torque wrench, Floor jack, trans jack, jack stands, Clutch Alignment tool, 2 jaw puller, bearing seal install tool, pilot bearing puller, snap ring pliers, philips, swivel 14mm sockets and long extensions.

  1. Disconnect battery, trust me.
  2. Raise vehicle and place on jack stands. I use wheel ramps for front and jacks under rear axle. On a flat level hard surface. (Garage). Truck was already high enough.
  3. In side vehicle remove, center console and shifter boots.
  4. Remove shifter knobs. They unscrew. normally really tight.
  5. Using snap ring pliers remove trans shifter.
  6. Drain transfercase oil. You can leave oil in but it will leak some when rear dshaft is pulled.
  7. Disconnect transfercase shifter at joint from below, remove shifter from inside.
  8. Remove exhaust Y pipe.
  9. Unplug all electrical connectors on trans.
  10. Unscrew and remove speedo cable from tcase. No oil will come out.
  11. Remove both drive shafts.
  12. Remove 2 starter bolts from trans side and leave starter wires connected and in vehicle.
  13. Remove the 2 14mm bolts holding on Clutch slave cylinder, zip tie up and out of the way. Do not disconnect hydraulic line.
  14. Remove both transmission mount bolts and 17mm nuts at the mount.
  15. Remove all visible lower 14mm bolts that connect trans to engine. They go in both directions.
  16. Put a Transmission jack or jack stand under transfer case and remove the 4 14mm bolts from Trans crossmember and remove crossmember, placing weight of trans/TC on Jack.
  17. Now lower the rear transmission enough so you can access the UPPER 14mm bolts.
  18. Remove all upper 14mm bolts with swivel sockets on 24" extensions.
  19. Now you should be ready to place trans jack under transmission/TC and remove both as a unit. Bolt trans to jack. 2 men are better than 1 here.

  20. Lower and remove unit from vehicle and set aside.

  21. Remove bearing and collar as unit from front of trans.
  22. To seperate collar from bearing: I use a round seal tool and a 2 jaw gear puller. see pic.
  23. Put clutch alignment tool in clutch disc.
  24. Now remove all 6 12mm Pressure plate bolts from flywheel.
  25. Remove clutch and pressure plate and discard.
  26. Remove pilot bearing bushing with suitable tool from crankshaft.

Installation:

  1. Insert new bushing in crankshaft.
  2. Check condition of flywheel, remove and resurface if damaged. I usually just rough up with sandpaper, just like brake job.
  3. Install clutch disc on flywheel with alignment tool.
  4. Install pressure plate and tighten in criss cross pattern see service manual. Tighten to torque specs.
  5. remove alignment tool.
  6. Put new bearing in bench vise with collar and press on.
  7. Put bearing on front of trans with a little grease inside collar.
  8. Raise trans an put back in.
  9. Put in the 14mm trans bolts first starting at the top. Leave trans leaning down.
  10. Install all Trans bolts and torque to specs.
  11. Install Starter.
  12. Install Slave cylinder.
  13. Install Trans mount.
  14. Install crossmember.
  15. Install both drive shafts
  16. Install y pipe
  17. Install Shifters
  18. Install center consoles.
  19. Remove fill plug on TC and fill to top of plug withDexron.
  20. Connect electrical connectors.
  21. Lower vehicle.
  22. reconnect battery.

modified pilot bearing puller.

Custom trans jack.

custom wrench for driveshaft removal