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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2003 Nissan Murano. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply Nissan PSF II 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
    G01199650Courtesy of NISSAN MOTOR CO., U.S.A.
  3. To fit rack Teflon ring on rack, use rack Teflon ring installation tool from tooth side. Compress rim of ring with the tool.
    Fig 2: Fitting Rack Teflon Ring
    G01199651Courtesy of NISSAN MOTOR CO., U.S.A.
  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.
    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 Oil Seal And Inserting Rack Assembly To Gear Housing Assembly
    G01199652Courtesy 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: Placing Oil Seal On Sheet
      G01199653Courtesy 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: Installing Rack Oil Seal (Inner) To Fit With Gear Housing Assembly
      G01199654Courtesy 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.
      Fig 6: Installing Outer Rack Oil Seal, Cover End Of Rack With An OHP Sheet
      G01199655Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Install end cover assembly to rack, move it to gear housing assembly.
  5. Using a 45 mm (1.77 in) open head (SST), tighten end cover assembly to the specified torque.

    Tightening torque: 58.9 - 73.5 N.m (6.0 - 7.4 kg.m, 44 - 54 ft.lb) 

    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.
    Fig 7: Caulking Cylinder At One Point
    G01199656Courtesy of NISSAN MOTOR CO., U.S.A.
  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 Nissan PSF II or equivalent to O-ring. Install O-ring to rear cover.
    NOTE: Do not reuse O-ring.
  9. Use a rear cover wrench (SST) to 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 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 ovehaul in advance.
    Fig 8: Measuring Adjusting Screw Height
    G01199657Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Rotate ten times throughout whole range of rack so that parts fit with each other.
  13. Measure pinion rotating torque within from -180° - +180°, make preload gauge (SST) and torque adapter (SST) in rack neutral position, then hold preload gauge (SST) at maximum torque.
    Fig 9: Measuring Pinion Rotating Torque With Preload Gauge
    G01199658Courtesy of NISSAN MOTOR CO., U.S.A.
  14. 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). Furthermore loosen it within from 20 - 40°.
  15. Measure pinion rotating torque with torque adapter (SST) and preload gauge (SST), then confirm whether their readings are within the specified range. If the readings are not within the specified ranges, readjust screw angle with adjusting screw. Change gear assembly to new one, if the readings are still not within the specified ranges, or the rotating torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb).
    Fig 10: Pinion Rotating Torque Graph
    G01199659Courtesy of NISSAN MOTOR CO., U.S.A.

    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) 

  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 Fig 11 . 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 range. If reading is outside of 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 11: Measuring Vertical Movement Of Rack
    G01199660Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 12: Vertical Movement Table
    G01199661Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install large-diameter side of boot to gear housing assembly.
    Fig 13: Installing Boot Clamp To Small-Diameter Side Of Boot
    G01199662Courtesy of NISSAN MOTOR CO., U.S.A.
  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. Lock new larger boot clamp securely with a suitable tool.
    NOTE:
    • Do not reuse boot clamp.
      Fig 14: Locking Boot Clamp With Suitable Tool
      G01199663Courtesy of NISSAN MOTOR CO., U.S.A.
    • Secure boot band so that dimension M as shown in Fig 15 satisfies the following:

    Dimension M: 

    Max: 3.5 mm (0.138 in) 

    Fig 15: Measuring M Dimension
    G01199664Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install cylinder tubes to gear housing assembly.
    Fig 16: Installing Cylinder Tubes To Gear Housing Assembly
    G01199665Courtesy of NISSAN MOTOR CO., U.S.A.

    Tightening torque: 19.7 - 26.4 N.m (2.0 - 2.6 kg.m, 15 - 19 in.lb) 

  23. Install lock nut and outer socket to inner socket.
  24. Tighten lightly tie-rod in specified length L, then tighten lock nut at specified torque. Refer to DISASSEMBLY AND ASSEMBLY  . Reconfirm if tie-rod length is within limit of specified length L. See Fig 17 .

    Tie-rod length L: 135.2 mm (5.32 in) 

    Fig 17: Measuring Length Of Tie-Rod
    G01199666Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessarily value given here.
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