Disassembly And Assembly: Assembly

Apply Genuine Nissan PSF or equivalent to O-ring. Put an O-ring into rack Teflon ring.
NOTE: Do not reuse O-ring.
Apply Genuine Nissan PSF or equivalent to rack Teflon ring, then heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack.

Fig 1: Heating Teflon Ring
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: Do not reuse rack Teflon ring.
To fit rack Teflon ring on rack assembly, use rack Teflon ring correcting tool (SST) from tooth side. Compress rim of ring with the tool.

Fig 2: Displaying Rack Teflon Ring Correcting Tool

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.
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: Displaying Rack Oil Seal With Inner & Outer Lips Facing Each Other
  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)]. 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 4: Displaying Rack With OHP Sheet
  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, and then make rack move in gear housing assembly, install rack oil seal (inner) to fit with gear housing assembly.
  
  Fig 5: Displaying Rack Oil Seal & Rack Teflon Ring In Gear Housing
  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 OHP sheet.
  
  Fig 6: Installing OHP Sheet On Rack End
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install end cover assembly to rack assembly, move it to gear housing assembly.
Using a 36 mm (1.42 in) open head (suitable tool), tighten end cover assembly at the specified torque.

Fig 7: Tightening End Cover With Open Head Tool
Courtesy 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.
After tightening end cover assembly, stake cylinder at one point as shown in Fig 8 using a punch. This will prevent end cover assembly from getting loose.

Fig 8: Displaying Area To Stake On Cylinder
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply Genuine Nissan PSF or equivalent to O-ring, then install O-ring to gear housing assembly.
NOTE: Do not reuse O-ring.
Install gear sub assembly to gear housing assembly.
Attach lock plate to rack assembly.

Fig 9: Attaching Lock Plate To Rack Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE:
Do not reuse lock plate.
1. Tack spacer ring to rack assembly.
  NOTE: Do not reuse spacer ring.
2. Install inner socket to lock plate.
3. Apply locking sealant (Three Bond IIIIB or equivalent) to the thread of inner socket. Screw inner socket into rack assembly and tighten at the specified torque.
4. Caulk lock plate at two points on rack slit.
5. Install spacer ring to lock plate as shown in Fig 9 .
  CAUTION: When installing spacer ring, avoid damaging it.
Decide neutral position of rack assembly.
1. Rack stroke (L) : 68.5 mm (2.697 in)
Install rear cover cap to gear sub assembly.
Apply multi-purpose grease to retainer, then install retainer, spring and adjust screw to gear housing assembly.
Apply thread locking adhesive (Three Bond TB IIIIB 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 overhaul in advance.

Fig 11: Displaying Adjusting Screw Height
Courtesy of NISSAN MOTOR CO., U.S.A.
With adjusting screw held in place, tighten lock nut to specified torque.
Rotate pinion ten times whole range of rack assembly so that parts get to fit each other.
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.

Fig 12: Displaying Preload Gauge & Torque Adapter
Courtesy of NISSAN MOTOR CO., U.S.A.
After loosening adjusting screw once, tighten it again with torque of 4.9 - 5.9 N.m (0.5 - 0.6 kg-m, 44 - 52 in-lb). After that loosen it within 20° to 40°.
With adjusting screw held in place, tighten lock nut to specified torque.
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 13: Displaying Maximum Variation & Turning Angle Relationship
Courtesy of NISSAN MOTOR CO., U.S.A.

Pinion Rotating Torque
1. Around neutral position [within+/-11.5 mm (0.453 in]
1. Average "A"
  1. 0.79 - 1.27 N.m (0.08 - 0.12 kg-m, 7 - 11 in-lb)
2. Maximum variation
  1. "B": 0.39 N.m (0.04 kg-m, 3 in-lb)
3. Other than above
  1. Average "A"
    1. 0.58 N.m (0.06 kg-m, 5 in-lb)
  2. Maximum variation "B"
    1. 1.86 N.m (0.19 kg-m, 16 in-lb)
Turn pinion fully to the end of the left with inner socket to gear housing assembly.
Set dial gauge to rack as shown in Fig 14 . Measure vertical movement of rack assembly when pinion is turned counterclockwise with torque of 4.9 N.m (0.5 kg-m, 43 in-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 out side 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 14: Setting Dial Gauge To Rack
Courtesy of NISSAN MOTOR CO., U.S.A.
Install large side of boot to gear housing assembly.
Install small side of boot to the mounting groove of inner socket boot.
Install boot clamp to the small side of boot.
Install boot clamp to the large side of boot.
NOTE: Do not reuse boot clamp.
1. Tighten large side of RH/LH boot with boot clamp (stainless steel wire).
  1. Wire length (L) : 370 mm (14.57 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, 22.1 lb).
3. Twist boot clamp as shown in Fig 15 , pay attention to relationship between winding and twisting directions.
4. Twisted point should face front of vehicle (* marked portion) with steering gear assembly installed on vehicle (to prevent interference with other parts).
  
  Fig 16: Displaying Twisted Point Facing Front Of Vehicle
  Courtesy 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 17: Displaying Wire Position In Relationship To Boot
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install cylinder tubes to gear housing assembly.
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".
1. Inner socket length (L) : 160 mm (6.30 in)
  NOTE: Perform toe-in adjusting after this procedure. Length achieved after toe-in adjustment is not necessary value given here.