Power Steering Gear And Linkage: Assembly

Using a heat gun, heat new teflon rack seal ring to approximately 40°C (104°F). Then place it onto rack.

Fig 1: Heating Teflon Rack Seal Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Using Tool, compress rack seal ring securely on rack.
Always insert Tool from the rack gear side.

Fig 2: Compressing Rack Seal Ring Securely On Rack Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert new rack oil seal.
- Place plastic film into rack oil seal to prevent damage by rack teeth.
- Do not forget to remove plastic film after rack oil seal is positioned properly.
- Make sure lips of rack oil seal face each other.
Fig 3: Inserting New Rack Oil Seal
Courtesy of NISSAN MOTOR CO., U.S.A.
Install rack oil seal and rack bushing with rack assembly.

Fig 4: Installing Rack Oil Seal And Rack Bushing With Rack Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly.

Fig 5: Insert Rack Oil Seal And End Cover Assembly To Rack
Courtesy of NISSAN MOTOR CO., U.S.A.
Fasten cylinder end cover assembly to gear housing by staking.

Fig 6: Fastening Cylinder End Cover Assembly To Gear Housing By Staking
Courtesy of NISSAN MOTOR CO., U.S.A.
Set rack gear in the neutral position.
1. Rack stroke "S":
  1. Refer to SDS, STEERING GEAR AND LINKAGE .
  Fig 7: Setting Rack Gear In Neutral Position
  Courtesy of NISSAN MOTOR CO., U.S.A.
Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool.
Make sure lip of oil seal faces up when installed.

Fig 8: Installing Seal Lip Into Pinion Housing Of Gear With A Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install pinion bearing adjusting shim(s).
- Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.
Fig 9: Installing Pinion Bearing Adjusting Shim(S)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install new pinion seal ring (made of Teflon) on pinion gear assembly.
- Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly.
- Make sure pinion seal ring is properly settled in valve groove.
Fig 10: Installing Pinion Seal Ring On Pinion Gear Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip.

Fig 11: Applying Coat Of Multi-Purpose Grease To Needle Bearing Roller
Courtesy of NISSAN MOTOR CO., U.S.A.
Install pinion assembly to rear housing.
Be careful not to damage pinion oil seal.

Fig 12: Installing Pinion Assembly To Rear Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply a coat of multi-purpose grease to new rear oil seal lip before installing rear housing.

Fig 13: Applying Coat Of Multi-Purpose Grease To Rear Oil Seal Lip
Courtesy of NISSAN MOTOR CO., U.S.A.
Ensure that the rack is centered. Install rear cover cap so that its protrusion is positioned as shown in figure.
Be careful not to damage worm ring and oil seal.
Install retainer, spring and adjusting screw temporarily.

Fig 14: Aligning Matching Mark On Rear Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install new lock plate.
- Attach lock plate 2 to side rod inner socket 1.
- Apply locking sealant to inner socket threads 3.
  Screw inner socket into rack 4 and tighten to specified torque.
- Clinch two places of lock plate at rack's groove.
CAUTION: To prevent scratching the boot, remove burrs from lock plate.

Fig 15: Installing Lock Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Tighten outer socket lock nut.
1. Tie-rod length "L":
  1. Refer to SDS, STEERING GEAR AND LINKAGE .
Measure rack stroke.
1. Rack stroke "S":
  1. Refer to SDS, STEERING GEAR AND LINKAGE .
  Fig 16: Measuring Rack Stroke And Tie-Rod Length
  Courtesy of NISSAN MOTOR CO., U.S.A.
Before installing boot, coat the contact surfaces between boot and tie-rod with grease.

Fig 17: Coating Contact Surfaces Between Boot And Tie-Rod With Grease
Courtesy of NISSAN MOTOR CO., U.S.A.