I recently burned out the clutch in my 2005 350Z at 35,000 miles. Car has never been raced or even thrashed very hard. Needless to say, I was pretty disappointed at this early failure and, of course, I was out of warranty. My local Nissan dealer wanted $2600 to replace the clutch which included a new $1150 flywheel. Thieves! After searching this and a couple of other Nissan forums, I found that others have also experienced premature clutch failures and Nissan has not come through.

The friction disc on the dual mass flywheel had been scarred by the rivets on the disk but only about .005”-.006” deep per my rough measurement. I spent a couple of days going around to machine shops only to discover no one could reface the friction plate. Nissan said it couldn’t be done and just wanted to sell me the new flywheel.

I know others have faced this same issue. $2600 for a clutch job and/or $1000+ for a new flywheel.

I am writing to report that I have found a guy in Minnesota who will reface your flywheel. The only reason no one else will do it is because the flywheel has to be disassembled to do the refacing. It is riveted together and nobody hot rivets anymore. Once the flywheel is disassembled, refacing the plate is a completely straightforward job.

I sent my flywheel to Alex Westling at Westling Machine in Milaca, Minnesota (near Minneapolis). He disassembled, refaced and had the flywheel back to me in less than a week. It looked like a new flywheel! I have it back in the car and things seem to be working fine. There is a question as to how long it will last, but my suspicion is that it will last at least as long as the first one. I will update this thread from time to time to report ongoing results.

But, the savings is hundreds of dollars. I’ll leave it to everybody to set their own deal with Alex but I can tell you that I saved about $2000 over taking it to the dealer by doing the job myself and having the flywheel refurbished. I replaced bushing, throw out bearing, clutch disk and pressure plate new from Nissan.

Now, doing a clutch job in your garage is not for the faint at heart. But it requires only basic tools and help from someone to get the trans remounted. Bottom line, it is really just a straight up clutch replacement about like any other car. If you’re so inclined and able, you can save yourself a ton of cash. I thought everyone might appreciate the info as an alternative.

You can reach Alex Westling at 612-390-5601 or alex@westlingmachine.com or check his website at www.westlingmachine.com . I’m pleased to respond to questions at admin@shoptalkforums.com.

Best of luck,

doc

 

When replacing the clutch do not machine the flywheel. this changes the clearances and will cause clutch engagement issues. Inspect flywheel for cracks or heat related damage, if none sand using 3M sanding disk or equivalent, if there is damage replace flywheel. I believe the torque specs on the pressure plate are 12-16 ft-lbs.

 

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I've been driving sticks for 30 years, and professional Commercial driver,and retired military/commercial Helicopter Pilot: controls finesse is my forte!I never replaced a clutch before due to wearing out and slipping - so:

2011 Nissan Frontier Pro-4X, Crew Cab, 4 X 4, 4.0L-V6, 6 Speed Manual XSMN:Never had that single flywheel - get up and go feel anyways!

- 1st Clutch slipping failure issue at 14,000 (18 months of around towndriving)

- 2nd Clutch slippage issue: 33,500 (3 1/2 years)...

I highly suspect it is all been caused by the dual-mass Flywheel not beingengineered to talk any work related Torque applications (Rapid decelerationdownshifting; constant 4x4 in snow conditions; reversing up incline with popupcamper trailer - always smell burn after that)!

I’m trying to find the specific Nissan Frontier Dual Mass Flywheel shopmanual inspection criteria. Yes, I emailed Nissan and asked them for thisinformation...I guess their lack of reply / silence is a "NO" so far!

Hmmm... I may need a Sopena or request for "Discovery" to get thatinformation: while I'm at it- request the number and data of other'scomplaining about this issue too! Then if a lot- I know a class action lawsuitlawyer in town already...

My truck maybe ready in a day or two - I did get NISSAN to pay the first$1200 of the $1800 estimate this time...so, they know something is rotten inDenmark, but don't want to admit it's totally their fault.

LuC Clutch website has a very good video how to test their clutches, so I'llprobably use that as a guide when I look at the dual-mass flywheel they tookout of my truck today.

http://www.schaeffler.com/remotemedien/media/_shared_media/08_media_library/01_publications/schaeffler_2/brochure/downloads_1/zms_special_tool_de_en.pdf

I'm still trying to figure out who supplies the clutches and maybe flywheelsfor the Frontier...

If it looks bad to me, I'll point that out to the dealer, and see if he'llcode this issue as the flywheel's fault, and 100% covered by power-trainwarrantee. If they still insist on the original split payment deal due toclutch/driver issues; I'm taking the flywheel to AAMCO and a couple of othertransmission shops for inspection and analysis. If they concur with theflywheel being defective- I'm going to file a complaint at my local SmallClaims Court for the money I was charged! Let a Judge decide if the flywheel isdefective and warrantee should have covered it all.

One last piece of advice-

Also post your complaint on the NHTSA website www.safecar.gov to let UncleSam know about this problem of premature clutch/flywheel problems that seem tobe systemic: through that website, recalls to truly fix all our vehicles at nocost can be made! In fact, write your congressman too! If a recall iseventually issued, due to complint submissions- think- REFUND for everyonealready taken to the cleaners over this issue!

After reading so many other post on so many other sites about this issue:Nissan is making a bundle charging owners to replace their faulty parts!

United We Stand- at www.safecar.gov

And you can signup for recall notices for up to 5 different vehicles, see ifthere are recalls for vehicles, check other's complaints, see if servicebulletins have been issued...go there ! www.safecar.gov now,and before buying another car or motorcycle in the future!

av8or-dave

(Don't pick a fight with a old man, because if he can't fight- he'll justkill you!)