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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: Heating Rack Teflon Ring With Dryer
    G03106823Courtesy 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
    G03106824Courtesy 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: Inserting Rack Assembly To Gear Housing Assembly
      G03106825Courtesy 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: Wrapping OHP Sheet Around Rack Tooth
      G03106826Courtesy 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 Position And Pushing Retainer
      G03106827Courtesy 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 And Covering End Of Rack With OHP Sheet
      G03106828Courtesy 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 Assembly At Specified Torque
    G03106829Courtesy of NISSAN MOTOR CO., U.S.A.
  6. 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.
  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: Identifying Caulking Point And Gear Hosing
    G03106830Courtesy 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: Identifying Adjusting Screw Height
    G03106831Courtesy 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
    G03106832Courtesy 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).

    Pinion rotating torque: 

    Around neutral position (within +/- 100°) Average "A": 

    0.8 - 2.0 N.m (0.09 - 0.20 kg-m, 7-17 in-lb) 

    Other than above (more than +/- 100°) 

    Maximum variation "B": 

    2.3 N.m (0.23 kg-m, 20 in-lb) 

    Fig 11: Reading Of Pinion Rotating Torque
    G03106833Courtesy 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
    G03106834Courtesy of NISSAN MOTOR CO., U.S.A.
    PINION ROTATING TORQUE SPECIFICATION

    Amount of vertical movement with rack Less than 0.265 mm (0.010 in)
    Measuring point  Axial direction of rack  5 mm (0.197 in) away from end of gear housing 
    Radius direction of rack  Shaft direction of adjusting screw 
  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 13: Install Boot Clamp
    G03106835Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Tighten large-diameter side of RH/LH boot with boot clamp (stainless wire).

      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 14: Wrapping Clamp Around Boot Groove For Two Turns
      G03106836Courtesy 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 15: Twisting Boot Clamp
      G03106837Courtesy 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 16: Installing Cylinder Tubes To Gear Housing Assembly
    G03106838Courtesy 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".

    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 17: Tightening Lightly Inner Socket In Specified Length
    G03106839Courtesy of NISSAN MOTOR CO., U.S.A.
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