AWD : Disassembly and Assembly: Assembly

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: Inserting Rack Oil Seal Into Rack Assembly Piston

   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.
5. Install end cover assembly to rack edge, and move rack oil seal (outer) until it contacts with gear housing assembly.
   Fig 6: Identifying End Cover Assembly To Rack Edge

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

Fig 8: Crimping Gear Housing Assembly

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

1. Apply thread sealant into the thread of inner socket.

   Use Genuine Medium Strength Thread Locking Sealant or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

L :  Refer to "RACK STROKE ".

Use Genuine High Performance Thread Sealant or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

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.
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°.
   Fig 11: Adjusting Pinion Rotating Torque Using Tools A And B

   Courtesy of NISSAN MOTOR CO., U.S.A.
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: Pinion Rotating Torque Graph

   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.
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.
     Fig 13: Identifying Gear Housing Assembly

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

1. Tighten large side of boot with boot clamp (stainless wire).

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

2. Wrap clamp around boot groove for two turns. Insert a flat-bladed 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).
   Fig 15: Identifying Dimension Of Boot Clamp

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Twist boot clamp as shown. Pay attention to relationship between winding and twisting directions.
   Fig 16: Identifying Boot Clamp Winding And Twisting Directions

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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 Boot Clamp Direction

   Courtesy of NISSAN MOTOR CO., U.S.A.
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: Bending Cut End Of Wire Toward Rack Axial

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

L :  Refer to "INNER SOCKET LENGTH ".

Fig 19: Adjusting Inner Socket To Standard Length L

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