Power Steering Gear And Linkage: Assembly

Using a heat gun, heat new teflon rack seal ring to approximately 40° C (104° F). Then place it onto rack.

Fig 1: Identifying Heat Gun & Rack Seal Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Using Tool, compress rack seal ring securely onto rack.

Fig 2: Compressing Rack Seal Ring Onto Rack
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: Always insert Tool from the rack gear side.
Insert new rack oil seal.
- Place plastic film into rack oil seal to prevent damage by rack teeth.
  
  Fig 3: Placing Plastic Film Into RackSeal
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Do not forget to remove plastic film after rack oil seal is positioned properly.
- Make sure lips of rack oil seal face each other.
Install center bushing and rack oil seal with rack assembly.

Fig 4: Installing Center Bushing & Rack Oil Seal
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly.

Fig 5: Inserting Rack Oil Seal & End Cover Assembly To Rack
Courtesy of NISSAN MOTOR CO., U.S.A.
Fasten end cover assembly to gear housing by staking.

Fig 6: Locating Clearance Between End Cover Assembly & Gear Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
Set rack gear in neutral position.
1. Rack stroke "S": Refer to STEERING GEAR AND LINKAGE .
Install adjustment shims and O-rings to gear sub-assembly.
- Install the same number of adjustment shims as before, regardless of whether or not gear sub-assembly is replaced.
- Discard old O-rings; replace with new ones.
Tighten gear subassembly securing bolts to specified tightening torque.
Ensure that the rack is centered. Install rear cover cap so that its protrusion is positioned as shown in Fig 9.

Fig 9: Locating Rear Cover Cap Protrusion Positioning
Courtesy of NISSAN MOTOR CO., U.S.A.
Install diaphragm spring into gear housing.
- Always install retainer, spring washer and diaphragm spring in that order.
- Make sure convex end (painted white) of diaphragm spring faces outward when installing.
Install spring seat retainer spring and adjusting screw temporarily.
Install lock plate to rack.
1. Temporarily install spacer ring to rack.
  NOTE: Discard old spacer ring; replace with a new one.
2. Install lock plate to inner socket.
  NOTE: Discard old lock plate; replace with a new one.
3. Apply a coat of locking sealant to inner socket threads. Screw inner socket into rack and tighten to specified torque.
4. Clinch lock plate at rack groove location (at two points).
5. Install spacer ring to lock plate as shown in Fig 11.
  
  Fig 11: Installing Spacer Ring To Lock Plate
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  NOTE: Be careful not to damage spacer ring during installation
Tighten outer socket lock nut.
1. Tie-rod length "L": Refer to STEERING GEAR AND LINKAGE .
Measure rack stroke.
1. Rack stroke "S": Refer to STEERING GEAR AND LINKAGE .
Before installing boot, coat the contact surfaces between boot and tie-rod with grease.

Fig 14: Locating Grease Area Between Boot & Tie-Rod
Courtesy of NISSAN MOTOR CO., U.S.A.
Install boot bands.
- Securely install boot band to boot groove and clinch the root section of the trapezoidal area.
- Make sure that there is a clearance of 3.5 mm (0.138 in) or less at the clinched section of the boot band. Refer to Fig 15.
  
  Fig 15: Locating Clearance Clinched Section Of Boot Band
  Courtesy of NISSAN MOTOR CO., U.S.A.
- After installing gear in vehicle, make sure that the clinched section of boot band is positioned toward the rear of vehicle (to prevent interference with adjacent parts).
  
  Fig 16: Identifying Boot Band Positioning
  Courtesy of NISSAN MOTOR CO., U.S.A.