Disassembly and Assembly: Assembly

1. Heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack assembly.
   CAUTION: Never reuse rack Teflon ring.
   Fig 1: Heating Rack Teflon Ring With Dryer

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install the Teflon ring correcting tool [SST: KV48104400 ( - )] from tooth side of rack to fit rack Teflon ring on rack. Compress the ring with tool.
   Fig 2: Identifying Teflon Ring Correcting Tool

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3. Apply recommended grease to rack oil seal, and then install rack oil seal in the following procedure. Then assemble rack assembly to gear housing assembly.
   CAUTION:

   • Install rack oil seal in a direction so that the lip of inner oil seal and the lip of outer oil seal face each other.
   • Never damage retainer sliding surface by rack assembly. Replace gear housing assembly if damaged.
   • Never damage gear housing assembly inner wall by rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage.
   • Never reuse rack oil seal.
   Fig 3: Identifying Rack Oil Seal & End Cover Assembly
   Courtesy of NISSAN MOTOR CO., U.S.A.
   1. Wrap an OHP sheet [approximately 70 mm (2.76 in) x 100 mm (3.94 in)]. Around rack assembly teeth to avoid damaging rack oil seal (inner). Install rack oil seal over sheet. Then, pull OHP sheet along with rack oil seal until they pass rack assembly teeth, and remove OHP sheet.
      Fig 4: Identifying Inner Rack Oil Seal

      Courtesy of NISSAN MOTOR CO., U.S.A.
   2. Insert rack oil seal (inner) into rack assembly piston (rack Teflon ring).
   3. Push retainer to adjusting screw side by hand, and move the rack assembly inside the gear housing assembly so that the rack oil seal (inner) can be pressed against the gear housing assembly.
      Fig 5: Identifying Rack Oil Seal, Gear Housing & Rack Teflon Ring

      Courtesy of NISSAN MOTOR CO., U.S.A.
   4. Wrap an OHP sheet [approximately 70 mm (2.76 in) x 100 mm (3.94 in)]. Around the edge to avoid damaging rack oil seal (outer). Install rack oil seal over sheet. Then, pull oil seal along with OHP sheet until they pass rack edge, and remove OHP sheet.
      Fig 6: Identifying OHP Sheet, Rack End, Rack Oil Seal & End Cover Assembly

      Courtesy of NISSAN MOTOR CO., U.S.A.
   5. Install end cover assembly to rack edge, and move rack oil seal (outer) until it contacts with gear housing assembly.
4. Tighten end cover assembly to specified torque using a 36 mm (1.42 in) open head (suitable tool).
   CAUTION: Never damage rack assembly. Replace it if damaged because it may cause fluid leakage.
   Fig 7: Tightening End Cover Assembly

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5. Crimp gear housing assembly at one point using a punch as shown in the figure so as to prevent end cover assembly from getting loose after tightening end cover assembly.
6. Apply recommended fluid to O-ring, and then install O-ring to gear housing assembly.
   Fig 8: Identifying Gear Housing Assembly Crimping Position

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7. Install gear-sub assembly to gear housing assembly.
   CAUTION: In order to protect oil seal from any damage, insert gear sub assembly straightly.
8. Install inner socket to gear housing assembly with the following procedure.
   1. Apply thread sealant into the thread of inner socket.

      Use Genuine Silicone RTV or equivalent.  Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .

9. Decide on the neutral position of the rack stroke (L).

   Standard 

   L:  Refer to RACK STROKE  .

   Fig 9: Identifying Neutral Position Of Rack Stroke

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10. Install rear cover cap to gear sub-assembly.
    CAUTION: Make sure that the projection of rear cover cap is aligned with the marking position of gear housing assembly.
11. Apply recommended thread locking sealant to the thread (2 turns thread), and then screw in the adjusting screw until it reaches height "H" from gear housing assembly measured before disassembling.
12. Move rack assembly 10 strokes throughout the full stroke so that the parts can fit with each other.
    Fig 10: Identifying Adjusting Screw Height

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13. Adjust pinion rotating torque with the following procedure.
    1. Measure pinion rotating torque within ±180° of neutral position of the rack assembly using tools. Stop the gear at the point where highest torque is read.
       Fig 11: Measuring Pinion Rotating Torque

       Courtesy of NISSAN MOTOR CO., U.S.A.

       A: Preload gauge [SST: ST3127S000 (J-25765-A)]

       B: Preload adapter [SST: KV48103400 ( - )]

    2. Loosen adjusting screw and retighten to 5.4 N.m (0.55 kg-m, 48 in-lb), and then loosen by 20 to 40°.
    3. Measure pinion rotating torque using tools to make sure that the measured value is within the standard. Readjust if the value is outside the standard. Replace steering gear assembly, if the value is outside the standard after readjusting, or adjusting screw rotating torque is 5 N.m (0.51 kg-m, 44 in-lb) or less.

       Pinion rotating torque 

       Around neutral position (within ±100°) average (A) : 1.3 - 2.5 N.m (0.14 - 0.25 kg-m, 12 - 22 in-lb) 

       Maximum variation (B) : 3.0 N.m (0.31 kg-m, 27 in-lb) 

       Fig 12: View Of Pinion Rotating Torque

       Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Apply recommended liquid gasket to inner socket and turn pinion fully to left with inner socket installed to gear housing assembly.
    5. Install dial gauge at 5 mm (0.20 in) (L) from the edge of gear housing assembly (1), and tooth point.
       Fig 13: View Of Dial Gauge & Edge Of Gear Housing Assembly

       Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Measure vertical movement of rack assembly when pinion is turned clockwise with torque of 19.6 N.m (2.0 kg-m, 14 ft-lb). Readjust adjusting screw angle if the measured value is outside the standard.

    Vertical movement : 0.265 mm (0.0104 in) 

    • If reading is outside of the specification, readjust screw angle with adjusting screw.
    CAUTION:

    • 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.
    • Never turn adjusting screw more than twice.
    • Replace steering gear assembly when adjusting screw is removed or turned more than twice.
14. Install large end of boot to gear housing assembly.
15. Install small end of boot to inner socket boot mounting groove.
16. Install boot clamp to boot small end.
    Fig 14: Identifying Boot & Boot Clamps

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17. Install boot clamp to the large side of boot with the following procedure.
    CAUTION: Never reuse boot clamp.
    1. Tighten large side of boot with boot clamp (stainless wire).

       Wire length (L) : 370 mm (14.57 in) 

       Fig 15: Identifying Wire Length

       Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Wrap clamp around boot groove for two turns. Insert a flatbladed screwdriver in loops on both ends of wire. Twist 4 to 4.5 turns while pulling them with force of approximately 98 N (10 kg, 22 lb).
    3. Twist boot clamp as shown. Pay attention to relationship between winding and twisting directions.
       Fig 16: Twisting Boot Clamp

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    4. Twisted area (A) of clamp is in the opposite side of adjusting screw (1) as shown in the figure (to prevent contact with other parts).
       Fig 17: Identifying Twisted Area Of Clamp

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    5. Bent cut end of the wire toward rack axial as shown in the figure after twisting the wire 4 to 4.5 turns so that cut end does not contact with boot.
    CAUTION: Keep gap from cylinder tube 5 mm (0.20 in) or more.
    Fig 18: Identifying Bending Position Of Wire End

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18. Install cylinder tubes to gear housing assembly.
19. Install low pressure piping.
20. Adjust inner socket to standard length (L), and then tighten lock nut to the specified torque. Check length again after tightening lock nut.

Standard 

L:  Refer to INNER SOCKET LENGTH  .

Fig 19: Identifying Inner Socket Length

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