Disassembly And Assembly: Disassembly

Remove EPS solenoid valve.
NOTE: Do not attempt to disassemble EPS solenoid valve.
Remove cylinder tubes from gear housing assembly.
Remove rear cover cap from gear sub assembly.
Measure adjusting screw height from gear housing assembly, then loosen lock nut.
Remove adjust screw, spring and retainer from gear housing assembly.
Remove mounting bolts of gear sub assembly, then remove gear sub assembly from gear housing assembly.

Fig 1: Displaying Gear Sub Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: Do not overhaul gear sub assembly because it is non overhaul part. If there is something wrong with gear sub-assembly, change it to new one.
Remove O-ring from gear housing assembly.
Loosen lock nut of outer socket, and remove outer socket.
Remove boot clamps of the small side and the large side, then remove boots.

Fig 2: Removing Boot Clamps & Boots
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: When removing boots, be careful not to damage inner socket and gear housing assembly. If they are damaged, change them to avoid oil leaks.
Move spacer ring to rack assembly side, raise caulking part (at two points of part A) of lock plate and loosen inner socket, then remove inner socket from rack assembly.
CAUTION: When removing lock plate, be careful not to damage the surface of rack assembly. If damaged, rack assembly surface will cause an oil leak. Therefore, if the rack assembly surface is damaged, replace rack assembly.
Drill out the clinching part of cylinder outer rim with a 3 mm (0.12 in) drill in 1.5 mm (0.059 in) depth.

Fig 3: Drilling Out Clinching Part Of Cylinder
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove end cover assembly with a open head (suitable tool).

Fig 4: Removing End Cover With Open Head Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful not to damage rack assembly. If it is damaged, replace rack assembly. Otherwise, oil leaks may result.
Pull rack assembly with rack oil seal out of gear housing assembly.
CAUTION: Be careful not to damage cylinder. If it is damaged, replace gear housing assembly. Otherwise, oil leaks may result.
Heat rack Teflon ring to approximately 40°C (104°F) with a dryer, then remove it and O-ring from rack.

Fig 5: Heating Teflon Ring With Dryer
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful not to damage rack. If it is damaged, change to a new one to avoid oil leaks.
Use a taped 29 mm (1.14 in) socket and an extension bar. Remove rack oil seal from gear housing assembly.

Fig 6: Removing Rack Oil Seal From Gear Housing Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful not to damage gear housing assembly and cylinder inner wall. If it is damaged, gear housing assembly must be replaced. Otherwise, oil leaks will result.