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Disassembly And Assembly: Assembly

  1. Apply Genuine Nissan PSF or equivalent to O-ring. Put an O-ring into rack Teflon ring.
    NOTE: Do not reuse O-ring.
  2. Heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack.
    NOTE: Do not reuse rack Teflon ring.
    Fig 1: Using Heat Dryer To Install O-ring
    G00725698Courtesy of NISSAN MOTOR CO., U.S.A.
  3. To fit rack Teflon ring on rack, use rack Teflon ring installation tool (SST) from tooth side. Compress rim of ring with the tool.
  4. Apply Multi-purpose grease to rack oil seal. Insert rack oil seal, then insert rack assembly to gear housing assembly.
    NOTE: Do not reuse rack oil seal.
    Fig 2: Fitting Rack Teflon Ring On Rack Using SST
    G00725699Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • When inserting rack assembly, do not damage retainer sliding part. If it is damaged, replace gear housing assembly.
    • When inserting rack assembly, do not damage cylinder inner wall. If it is damaged, it may cause oil leaks. Replace gear housing assembly.
    • Attach rack oil seal. Both inner lip and outer lip should face each other.
    Fig 3: Attaching Rack Oil Seal
    G00725700Courtesy of NISSAN MOTOR CO., U.S.A.
    1. To avoid damaging inner rack oil seal, wrap an OHP sheet [approximately. 70 mm (2.76 in) x 100 mm (3.94 in) around rack tooth. Place oil seal on sheet. Then, pull oil seal along with OHP sheet until they pass the toothed section of rack, then remove it.
      Fig 4: Installing Inner Oil Seal Using OHP Sheet
      G00725701Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Insert rack oil seal (inner) to piston (rack Teflon ring) position and push retainer to adjust screw side with fingers lightly, and then make rack move in gear housing assembly, install rack oil seal (inner) to fit with gear housing assembly.
      Fig 5: Inserting Rack Oil Seal To Piston
      G00725702Courtesy of NISSAN MOTOR CO., U.S.A.
    3. When installing outer rack oil seal, cover the end of rack with an OHP sheet [70 mm (2.76 in) x 100 mm (3.94 in)]. It will avoid damaging rack oil seal. Then place oil seal on sheet. Pull rack oil seal along with OHP sheet until they pass rack end. Then remove OHP sheet.
    4. Install end cover assembly to rack, move it to gear housing assembly.
      Fig 6: Using OHP Sheet To Install Outer Rack Oil Seal
      G00725703Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Using a 45 mm (1.77 in) open head (suitable tool), tighten end cover assembly at the specified torque.
    CAUTION: Do not damage rack surface. If it is damaged, it may cause oil leaks. Replace rack assembly.
    Fig 7: Tightening End Cover Assembly
    G00725704Courtesy of NISSAN MOTOR CO., U.S.A.
  6. After tightening end cover assembly, stake cylinder at one point as shown in the figure using a punch. This will prevent end cover from getting loose.
  7. Install sub-gear assembly to gear housing assembly.
    CAUTION: In order to protect oil seal from any damage, insert sub-gear assembly out straightly.
  8. Apply Genuine Nissan PSF or equivalent to O-ring. Install O-ring to rear cover.
    NOTE: Do not reuse O-ring.
    Fig 8: Staking Cylinder After Tightening End Cover Assembly
    G00725705Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Use a rear cover wrench (SST), install rear cover to gear housing assembly.
  10. Confirm projection on rear cover cap nearly fit with marking position on gear housing assembly.
  11. Apply thread locking adhesive (Three Bound TB1111B or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ) to the thread of adjusting screw to the adjusting screw height from gear housing assembly. The adjusting screw height is the same as it was measured in the overhaul in advance.
  12. Rotate pinion ten times whole range of rack so that parts get to fit with each other.
    Fig 9: Adjusting Screw Height
    G00725706Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Measure pinion rotating torque within from -180° to +180°, make preload gauge (SST) and torque adapter (SST) in rack neutral position, then hold preload gauge (SST) at maximum torque.
  14. After loosening adjusting screw once, tighten it again with torque of 5.4 N.m (0.55 kg-m, 48 in-lb). After that loosen it within 20° to 40°.
    Fig 10: Measuring Pinion Rotating Torque With Torque Wrench
    G00725707Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Measure pinion rotating torque with torque adapter (SST) and preload gauge (SST), then confirm whether it's reading is within the specified value. If the reading is not within the specified value, readjust screw angle with adjusting screw. Change gear assembly to new one, if the reading is still not within the specified value or the rotating torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb).
    1. Pinion rotating torque: Around neutral position (within+/-100°) 
    2. Average "A": 0.8 - 2.0 N.m (0.09 - 0.20 kg-m, 7 - 17 in-lb) 
    3. Other then above (more than +/-100°) 
    4. Maximum variation "B": 2.3 N.m (0.23 kg-m, 20 in-lb) 
    Fig 11: Measure Pinion Rotating Torque With Torque Adapter & Preload Gauge
    G00725708Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Turn pinion fully to the end of the left with inner socket to gear housing assembly.
  17. Set dial gauge to rack as shown in the figure. Measure vertical movement of rack when pinion is turned counterclockwise with torque of 19.6 N.m (2.0 kg-m, 14 ft-lb). Check reading is within the specified value. If reading is outside of the specification, readjust screw angle with adjusting screw. If reading is still outside of specification, or if the rotating torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb), replace steering gear assembly.
    Fig 12: Setting Dial Gauge To Rack
    G00725709Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 13: Displaying Vertical Movement Of Rack Specifications
    G00725710Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install large-diameter side of boot to gear housing assembly.
  19. Install small-diameter side of boot to the mounting groove of inner socket boot.
  20. Install boot clamp to the small-diameter side of boot.
  21. Install boot clamp to the large-diameter side of boot.
    NOTE: Do not reuse boot clamp.
    Fig 14: Installing Large-Diameter Side Of Boot
    G00725711Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Tighten large-diameter side of RH/LH boot with boot clamp (stainless wire).
      1. Wire length "L" : 390 mm (15.35 in) 
    2. After wrapping clamp around boot groove for two turns, insert screwdriver in loop on both ends of wire. Twist 4 to 4.5 turns while pulling with a force of approx. 98 N (10 kg, 22.1 lb).
      Fig 15: Tightening Large-Diameter Side Of Boot
      G00725712Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Twist boot clamp as shown in the figure, pay attention to relationship between winding and twisting directions.
    Fig 16: Twisting Boot Clamps
    G00725713Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install cylinder tubes to gear housing assembly.
  23. Install lock nut and outer socket to inner socket.
    Fig 17: Installing Cylinder Tubes
    G00725714Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Tighten lightly inner socket in specified length "L", then tighten lock nut at specified torque. Refer to DISASSEMBLY AND ASSEMBLY  . Reconfirm if inner socket length is within limit of specified length "L".
    1. Inner socket length "L" : 135.2 mm (5.32 in) 
      CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessary value given here.
      Fig 18: Tighten Inner Socket In Specified Length "L"
      G00725715Courtesy of NISSAN MOTOR CO., U.S.A.
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