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Home › Infiniti › 2006 › FX45 › Repair and Diagnosis › Steering › Power Steering System › Power Steering Gear And Linkage › Disassembly and Assembly › Assembly

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.
    Fig 1: Heating Rack Teflon Ring
    G04076763Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Do not reuse rack Teflon ring.
  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.
    Fig 2: Inserting Rack Oil Seal
    G04076764Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Do not reuse rack oil seal.
    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: Attaching Rack Oil Seal
      G04076765Courtesy 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
      G04076766Courtesy 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 (Inner) To Piston (Rack Teflon Ring) Position
      G04076767Courtesy 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: Identifying Outer Rack Oil Seal
      G04076768Courtesy 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.
    Fig 7: Tightening End Cover Assembly
    G04076769Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not damage rack surface. If it is damaged, it may cause oil leaks. Replace rack assembly.
  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.
    Fig 8: Identifying Cylinder Caulking Point
    G04076770Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Do not reuse O-ring.
  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 Screw Adjusting Height
    G04076771Courtesy 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
    G04076772Courtesy 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).
    Fig 11: Identifying Pinion Rotating Torque Readings
    G04076773Courtesy of NISSAN MOTOR CO., U.S.A.

    Pinion rotating torque: 

    Around neutral position (within+/-100°) 

    Average "A": 

    0.8 - 2.0 N.m (0.08 - 0.20 kg-m, 7 - 18 in-lb) 

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

    Maximum variation "B": 

    2.3 N.m (0.23 kg-m, 20 in-lb) 

  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: Measuring Vertical Movement Of Rack
    G04076774Courtesy of NISSAN MOTOR CO., U.S.A.
    RACK VERTICAL MOVEMENT AND MEASURING POINT

    Amount of vertical movement with rack Less than 0.265 mm (0.01 in)
    Measuring point Axial direction of rack 5 mm (0.2 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.
    Fig 13: Identifying Boot Clamps
    G04076775Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Do not reuse boot clamp.
    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 lb).
      Fig 14: Identifying Stainless Steel Wire Length
      G04076776Courtesy 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
      G04076777Courtesy 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: Identifying Cylinder Tubes To Gear Housing Assembly
    G04076778Courtesy 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: Identifying Tie Rod Components And Rod Length Measurement Area
    G04076779Courtesy of NISSAN MOTOR CO., U.S.A.
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