Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Nissan 350Z. However, it is still accessible from the selected car via links, so may be relevant.

Apply Genuine NISSAN PSF or equivalent to O-ring. Put an O-ring into rack Teflon ring.
NOTE: Do not reuse O-ring.
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: Heating Rack Teflon Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
To fit rack Teflon ring on rack, use rack Teflon ring installation tool (SST) from tooth side. Compress rim of ring with the tool.

Fig 2: Installing Rack Teflon Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply Multi-purpose grease or equivalent to rack oil seal. Insert rack oil seal, then insert rack to gear housing assembly.
NOTE: Do not reuse rack oil seal.
CAUTION:
- When inserting rack, do not damage retainer sliding part. If it is damaged, replace gear housing assembly.
- When unstring rack, 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: Inner & Outer Rack Oil Seal
Courtesy 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: Pulling OHP Sheet With Rack Oil Seal
  Courtesy 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 in with gear housing assembly.
  
  Fig 5: Inserting Rack Oil Seal (Inner) To Piston (Rack Teflon Ring)
  Courtesy 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: Installing Outer Rack Oil Seal
  Courtesy of NISSAN MOTOR CO., U.S.A.
Using a 42 mm (1.65 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
Courtesy of NISSAN MOTOR CO., U.S.A.
After tightening end cover assembly, caulk cylinder at one point as shown in the figure using a punch. This will prevent end cover from getting loose.
Apply Genuine NISSAN PSF or equivalent to O-ring. Install O-ring to gear housing assembly.
NOTE: Do not reuse O-ring.

Fig 8: Caulking Cylinder At Caulking Point
Courtesy of NISSAN MOTOR CO., U.S.A.
Install gear sub-assembly to gear housing assembly.

Fig 9: Installing Gear Sub-Assembly To Gear Housing Assembly With Torque Specifications
Courtesy of NISSAN MOTOR CO., U.S.A.
Decide neutral position of rack gear.
- Rack stroke "L" : 64.5 mm (2.54 in)
Fig 10: Measuring Rack Stroke
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the projection part (Tip) of rear cover cap to gear sub-assembly as shown in the figure.

Fig 11: Installing Projection Part (Tip) Of Rear Cover Cap To Gear Sub-Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply thread locking adhesive (Three Bond TB1111B or equivalent) 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.
Rotate pinion ten times whole range of rack so that parts get to fit with each other.

Fig 12: Measuring Adjusting Screw Height
Courtesy of NISSAN MOTOR CO., U.S.A.
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.
After loosening adjusting screw once, tighten it again with torque of 4.9 - 5.9 N.m (0.50 - 0.60 kg-m, 44 - 52 in-lb). After that loosen it within from 20° to 40°.

Fig 13: Measuring Pinion Rotating Torque
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure pinion rotating torque with torque adapter (SST) and preload gauge (SST), then confirm whether its 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)
- Pinion rotation torque: Around neutral position (within +/-100°)
- Average "A": 0.8 - 2.0 N.m (0.09 - 0.20 kg-m, 7 - 17 in-lb)
  
  Fig 14: Measuring Pinion Turning Torque
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Other than above (more than +/-100°)
- Maximum variation "B": 2.3 N.m (0.23 kg-m, 20 in-lb)
Turn pinion fully to the end of the left with tie-rods to rack.
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 15: Setting Dial Gauge On Rack
Courtesy of NISSAN MOTOR CO., U.S.A.

Specified value

Fig 16: Rack Specified Value
Courtesy of NISSAN MOTOR CO., U.S.A.
Install large-diameter side of boot to gear housing assembly.
Install small-diameter side of boot to the mounting groove of inner socket boot.
Install boot clamp to the small-diameter side of boot.
Install boot clamp to the large-diameter side of boot.
NOTE: Do not reuse boot clamp.

Fig 17: Installing Boot Clamp
Courtesy of NISSAN MOTOR CO., U.S.A.
1. Tighten large-diameter side of RH/LH boot with boot clamp (stainless wire).
  - Wire length "L" : 370 mm (14.567 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 18: Tightening Large-Diameter Side Of RH/LH Boot With Boot Clamp (Stainless Wire)
  Courtesy 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 19: Twisting Boot Clamp
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Confirm the twisted point with clamp faces in the opposite direction to adjusting screw within 30° as shown in the figure.
  
  Fig 20: Dimensions Of Adjusting Screw
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. After twisting wire 4 to 4.5 turns, bend cut end of wire. Cut end of wire should not touch boot. Be sure wire end is at least 5 mm (0.20 in) away from clearance for tube.
  
  Fig 21: Twisting Angle
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install cylinder tubes to gear housing assembly.

Fig 22: Installing Cylinder Tubes To Gear Housing Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
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".
- Inner socket length "L" : 107.7 mm (4.240 in)
CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessarily value given here.

Fig 23: Inner Socket Length
Courtesy of NISSAN MOTOR CO., U.S.A.