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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2003 Infiniti M45. However, it is still accessible from the selected car via links, so may be relevant.
  1. Put an O-ring into rack.
    NOTE: Do not reuse rack O-ring.
  2. Heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to rack.
    NOTE: Do not reuse rack Teflon ring.
    Fig 1: Heating Rack Teflon Ring
    G02025405Courtesy of NISSAN MOTOR CO., U.S.A.
  3. To fit Teflon ring on rack, use Teflon ring installation tool (special service tool) from tooth side. Compress the rim of ring with tool. Then, put O- ring on Teflon ring.
    Fig 2: Installing Teflon Ring On Rack
    G02025406Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Insert rack oil seal.
    NOTE: Do not reuse rack oil seal.
    1. To avoid damaging inner rack oil seal, wrap an OHP sheet [approx. 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 3: Wrapping OHP Seat Around Rack Tooth
      G02025407Courtesy of NISSAN MOTOR CO., U.S.A.
      2. 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 leak. Replace gear housing assembly.
      Fig 4: Inserting Rack Oil Seal
      G02025408Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Insert rack oil seal (inner) to piston (rack Teflon ring) position and push retainer to adjusting screw side with fingers lightly, and then make rack move in gear housing assembly, install rack oil seal (inner) to fit in with gear housing assembly.
    3. When installing outer rack oil seal, end cover 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 the rack end. Install rack oil seal in place using end cover assembly. Then remove OHP sheet.
    4. Install end cover, move rack to gear housing assembly.
      Fig 5: Installing Rack Oil Seal Using End Cover Assembly
      G02025409Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Attach rack oil seal. Both inner lip and outer lip should face each other.
      Fig 6: Attaching Rack Oil Seal
      G02025410Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Using a 42 mm (1.65 in) open head (suitable tool), tighten end cover assembly at the specified torque.
    NOTE: Do not damage rack surface. If it is damaged, it may cause oil leak. Replace rack assembly.
    1. Tightening torque: 
    2. 58.9 - 73.5 N.m (6.0 - 7.4 kg-m, 44 - 54 ft-lb) 
    Fig 7: Tightening End Cover Assembly
    G02025411Courtesy of NISSAN MOTOR CO., U.S.A.
  6. After tightening end cover, caulk cylinder at one point as shown in the figure using a punch. This will prevent end cover from getting loose.
    Fig 8: Caulking Cylinder
    G02025412Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Assemble an O-ring to gear housing assembly.
    NOTE: Do not reuse O-ring.
  8. Install sub-gear assembly to gear housing assembly, then tighten bolts at the specified torque.
    1. Tightening torque: 
    2. 15.7 - 20.5 N.m (1.6 - 2.0 kg-m, 12 - 15 ft-lb) 
    Fig 9: Tightening Gear Housing Assembly Bolts
    G02025413Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Attach lock plate to rack.
    NOTE: Do not reuse lock plate.
    1. Tack spacer ring to rack.
      NOTE: Do not reuse spacer ring.
    2. Install lock plate to inner socket.
    3. Apply thread lock adhesive (Three Bond 1324 or equivalent) to thread of inner socket. Screw inner socket into rack and tighten at specified torque.
      Fig 10: Attaching Lock Plate To Rack
      G02025414Courtesy of NISSAN MOTOR CO., U.S.A.
      1. Tightening torque : 79 - 98 N.m (8.1 - 9.9 kg-m, 59 - 72 ft-lb) 
    4. Caulk lock plate at two points on rack slit.
    5. Install spacer ring to lock plate as shown in the figure.
      NOTE: When installing spacer ring, avoid damaging it.
  10. Decide neutral position of rack gear.
    1. Rack stroke "L" : 60mm (2.36 in) 
    Fig 11: Identifying Rack Gear Neutral Position Point
    G02025415Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install the projection part (Tip) of rear cover cap to sub-gear assembly as shown in the figure.
    Fig 12: Installing Projection Part (Tip) Of Rear Cover Cap
    G02025416Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Apply thread locking adhesive (Three Bond TB1111B or equivalent) to the thread of adjusting screw, and screw it to the projection height from gear housing assembly. The projection height is the same as it was measured in the overhaul in advance.
  13. Rotate ten times throughout whole range of pinion so that parts fit with each other.
    Fig 13: Applying Thread Locking Adhesive To Thread Of Adjusting Screw
    G02025417Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Measure pinion rotation torque within from -180° to +180° make preload gauge (special service tool) turn at the speed of 2 - 3 rpm in the rack neutral position, then hold preload gauge (special service tool) at maximum torque.
  15. 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° to 40°.
    Fig 14: Measuring Pinion Rotation Torque
    G02025418Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Measure pinion rotation torque with preload gauge (special service tool), then confirm whether its reading is within specified range. If reading is not within specified range, readjust screw angle with adjusting screw. Replace gear assembly with new one, if reading is still not within specified range or rotation torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb).
    1. Pinion rotation torque: 
    2. Around neutral position (within +/-100°) 
    3. Average "A": 
    4. 0.8 - 2.0 N.m (0.09 - 0.20 kg-m, 7 - 17 in-lb) 
    Fig 15: Turning Torque And Angle Graph
    G02025419Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Other than above (more than +/-100°) 
    2. Maximum variation "B": 
    3. 2.3 N.m (0.23 kg-m, 20 in-lb) 
  17. Turn pinion fully to end of left with tie-rods to rack.
  18. 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 specified range. If reading is outside of specification, readjust screw angle with adjusting screw. If reading is still outside of specification, or if the rotation torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb), replace steering gear assembly.
    Fig 16: Measuring Vertical Movement Of Rack
    G02025420Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 17: Rack Vertical Movement Amount Chart
    G02025421Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install boot of large-diameter side to gear housing assembly.
  20. Install boot of small-diameter side to inner socket boot mounting groove.
  21. Install boot clamp to small-diameter side of boot.
    Fig 18: Applying Thread Locking Adhesive To Boot Clamps
    G02025422Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install boot clamp to boot of the large-diameter side.
    1. Twist boot clamp (stainless wire) of the large diameter side for LH/RH boots.
      1. Wire length "L" 
      2. LH (sub-gear assembly side) : 390 mm (15.35 in) 
      3. RH (end cover assembly side) : 410 mm (16.14 in) 
    2. After twisting 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 19: Twisting Boot Clamps
      G02025423Courtesy 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 20: Twisting Boot Clamp
      G02025424Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Bend the twisted wire to radius direction of rack, then confirm the twisted point with clamp faces in the opposite direction to adjusting screw within 90° as shown in the figure.
      Fig 21: Confirming Clamp Faces Direction To Adjusting Screw
      G02025425Courtesy of NISSAN MOTOR CO., U.S.A.
    5. After twisting wire 4 to 4.5 turns, bend cut end of wire. Cut end of wire should not touch boot. Be sure wire end is at least 5 mm (0.20 in) away from clearance for tube.
      Fig 22: Identifying Wire End Cut
      G02025426Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install new O-ring to sub-gear assembly and install EPS solenoid valve to it, then tighten bolts at specified torque.
    1. Tightening torque: 
    2. 6.9 - 11 N.m (0.71 - 1.1 kg-m, 61 - 97 in-lb) 
  24. Install cylinder-tubes to gear housing assembly. Tighten flared nuts at specified torque.
    1. Tightening torque: 
    2. 19.7 - 26.4 N.m (2.0 - 2.6 kg-m, 15 - 19 ft-lb) 
    Fig 23: Installing Cylinder-Tubes To Gear Housing Assembly
    G02025427Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install lock nut and outer socket to inner socket, then tighten lock nut temporarily until length of tie-rod reaches to specified value. On specified tightening torque with lock nut, refer to "DISASSEMBLY AND ASSEMBLY  ".
    1. Tie-rod length "L" : 160 mm (6.30 in) 
      NOTE: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessarily value given here.
      Fig 24: Installing Lock Nut And Outer Socket To Inner Socket
      G02025428Courtesy of NISSAN MOTOR CO., U.S.A.
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