Blusteele Survivor Stage 2 Clutch & Flywheel Installation Guide: Nissan Navara D40 & Pathfinder R51 (YD25 2.5L)

If you own a Nissan Navara D40 or Pathfinder R51 powered by the YD25 2.5-litre diesel engine, chances are you will eventually face dual-mass flywheel failure. In this guide, we break down our conversion from the factory dual-mass setup to a heavy-duty single-mass flywheel and a Blusteele Survivor Stage 2 Ceramic Button Clutch Kit.

1. Understanding the Options & What's in the Box

These vehicles came with two different clutch sizes from the factory: a 250mm and a 275mm. The 275mm is rare, so for this installation, we are using the much more common 250mm kit.

The Blusteele Survivor Series kit is exceptionally comprehensive and includes:

• Single-Mass Flywheel: Replaces the failure-prone factory dual-mass unit. It features claw-groove technology for improved cooling.

• Heavy-Duty Pressure Plate: Built with SGI iron technology for high clamp loads, complete with patented do-lock bolts featuring serrated edges (eliminating the need for spring washers).

• Stage 2 Ceramic Button Plate: A sprung-center, cushioned button plate designed to combine high torque capacity with smooth street drivability.

• Bearings & Seals: Includes a spigot bush, a quality pre-packed thrust bearing, and—crucially—a rear main seal (which many kits leave out).

• Extras: Clutch alignment tool, a small tube of grease, a factory individual test report, and detailed installation notes with torque settings.

2. Pre-Installation Testing: Clamp Load & Pedal Pressure Myths

Clamp Load Testing

Before fitting, we tested the factory pressure plate against the Blusteele unit using a simulated disc thickness of 8.4mm:

• Old Factory Pressure Plate: Maxed out at roughly 700 kg of clamp load.

• Blusteele Survivor Pressure Plate: Delivered a massive 1,300 kg of clamp load—exceptional for a heavy-duty 4WD upgrade.

Dispelling the "Heavy Pedal" Myth

A common misconception is that a heavy-duty clutch with high clamp load equates to a heavy, leg-tiring pedal. We measured the actual downward force required at the pedal:

• Old Standard Clutch: ~20 to 22 kg of force.

• New Blusteele Survivor Clutch: ~15.5 kg of force. Despite nearly doubling the clamp load, the pedal actually became lighter and smoother to operate.

3. Step-by-Step Installation Notes

1. Remove the Gearbox: Once dropped, we confirmed that while the old friction disc wasn't completely worn out, the dual-mass flywheel had completely failed and was falling apart.

2. Prep the Crank & Seal: Replace the rear main seal, fit the new spigot bearing, and torque down the single-mass flywheel and cover bolts using Loctite. Use the alignment tool to center the friction plate before final tightening.

3. ⚠️ Crucial Warning (Crank Angle Sensor): The installation instructions explicitly state to remove the crank angle sensor before pulling or reinstalling the gearbox to prevent accidental damage. Don't skip this step—forgetting it can easily cost you a new sensor!

4. Reinstall Gearbox: Bolt the transmission back up, ensuring all bellhousing bolts and components are properly torqued.

4. Road Testing & Bedting-In Period

With everything reinstalled, the car was taken out for a test drive.

• First Impressions: The clutch pedal feel is instantly and unbelievably lighter. Engagement is remarkably smooth, without the aggressive grabby nature typically associated with ceramic button clutches.

• The Bedting-In Process:

  • Drive the vehicle normally for the first 1,000 to 1,500 km (approx. 1 to 2 weeks).

  • Avoid heavy towing and off-roading during this period to allow the components to bed in properly.

  • Note: You will notice the pedal pressure tighten up slightly as the friction material fully seats and makes 100% contact.

The Verdict

Switching from the failure-prone dual-mass setup to the Blusteele Survivor Stage 2 kit completely transforms how the Navara and Pathfinder drive. It offers phenomenal clamp load and better responsiveness while actually reducing pedal effort.