Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Nissan Titan. 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 from tooth side. Compress rim of ring using Tool.
Tool number : KV48104400 (-)

Fig 2: Fitting Rack Teflon® Ring On Rack
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply multi-purpose grease to rack oil seal. Insert rack oil seal, then insert rack assembly to gear housing assembly.
CAUTION:
- Do not reuse rack oil seal.
- 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: Identifying Seal Orientation
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 teeth. Place oil seal on sheet. Then, pull oil seal along with OHP sheet until they pass the toothed section of rack, then remove sheet.
  
  Fig 4: Pulling On 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. Then make rack move in gear housing assembly and install rack oil seal (inner) to fit with gear housing assembly.
  
  Fig 5: Installing Rack Oil Seal (Inner)
  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 sheet.
  
  Fig 6: Installing Outer Rack Oil Seal
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install end cover assembly to rack, move it to gear housing assembly.
Using a 45 mm (1.77 in) open head wrench or suitable tool, tighten end cover assembly to specification.
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 using a punch. This will prevent end cover from getting loose.

Fig 8: Caulking Cylinder
Courtesy of NISSAN MOTOR CO., U.S.A.
Install sub-gear assembly to gear housing assembly.
CAUTION: Oil seal may be damaged if sub-gear assembly is not installed correctly.
Apply Genuine NISSAN PSF or equivalent to O-ring. Then install O-ring to rear cover.
NOTE: Do not reuse O-ring.
Install rear cover to gear housing assembly using Tool.
Tool number : - (J-46213)
Make sure projection on rear cover cap aligns with mark on gear housing assembly.
Apply thread locking sealant to the thread of the adjusting screw. Then set adjusting screw height from gear housing assembly. The adjusting screw height is the same as it was measured previously.

Fig 9: Setting Adjusting Screw Height
Courtesy of NISSAN MOTOR CO., U.S.A.
Rotate pinion ten times through entire rack range to seat gears and to check operation.
With steering gear in neutral position, measure pinion rotating torque using Tool from within -180° to +180°, while applying and holding maximum torque to pinion gear.
Tool number : ST3127 S000 (J25765-A), -KV48103400 (-)

Fig 10: Measuring Pinion Rotating Torque
Courtesy of NISSAN MOTOR CO., U.S.A.
After loosening adjusting screw once, tighten it again with torque of 5.4 N.m (0.55 kg-m, 48 in-lb). Then loosen it within 20° - 40°.
Measure pinion rotating torque using Tool, then confirm whether the reading is within the specified value. If the reading is not within the specified value, readjust screw angle with adjusting screw. 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), replace the steering gear assembly.

Fig 11: Pinion Rotating Torque Chart
Courtesy 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)
Turn pinion to the full left lock position with inner socket to gear housing assembly.
Mount dial gauge to rack as shown. 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 if 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 the steering gear assembly.

Fig 12: Measuring Vertical Movement Of Rack
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig 13: Vertical Movement Of Rack Chart
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.

Fig 14: Installing Boot To Gear Housing Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install boot clamps and crimp securely.

Fig 15: Installing Boot Clamps
Courtesy of NISSAN MOTOR CO., U.S.A.
Install cylinder tubes to gear housing assembly.
Install lock nut and outer socket to inner socket.
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".