Disassembly and Assembly

Disassembly





1. Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference.
Refer to step 12 of "Adjustment" for reference torque data.
- Before measuring, disconnect cylinder tube and drain fluid.
- Use soft jaws when holding steering gear housing. Handle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise.
2. Remove pinion gear.
- Be careful not to damage pinion gear when removing pinion seal ring.
3. Remove tie-rod outer sockets and boots.





4. Loosen tie-rod inner socket by prying up staked portion, and remove socket.
5. Remove retainer.
6. Remove pinion assembly.
7. Use a 2 to 2.5 mm (0.079 to 0.098 inch) diameter drill to completely remove staked portion of gear housing end.





8. Remove gear housing end cover assembly with Tool.
9. Draw out rack assembly.
10. Remove rack seal ring.
- Using a heat gun, heat rack seal to approximately 40°C (104°F).
- Remove rack seal ring.
- Replace rack seal ring and O-ring with new ones.
Be careful not to damage rack.





11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar.
Do not scratch inner surfaces of pinion housing.

Inspection
Thoroughly clean all parts in cleaning solvent or Genuine Nissan PSF II or equivalent. Blow dry with compressed air, if available.

BOOT
- Check condition of boot. If cracked excessively, replace it.
- Check boots for accumulation of power steering fluid.

RACK
Thoroughly examine rack gear. If damaged, cracked or worn, replace it.

PINION ASSEMBLY
- Thoroughly examine pinion gear. If pinion gear is damaged, cracked or worn, replace it.
- Check that all bearings roll freely. Ensure that balls, rollers and races are not cracked, pitted or worn. Replace if necessary.

TIE-ROD OUTER AND INNER SOCKET





- Check ball joint for swinging force.
Tie-rod outer ball joint:
4.9 - 46.1 N
(0.5 - 4.7 kg, 1.1 - 10.4 lb.)
Tie-rod inner ball joint:
7.8 - 65.7 N
(0.8 - 6.7 kg, 1.8 - 14.8 lb.)





- Check ball joint for rotating torque.
Tie-rod outer ball joint: 0.29 - 2.94 Nm (3.0 - 30.0 kg-cm, 2.6 - 26.0 inch lbs.)
Tie-rod inner ball joint: 1.0 - 7.8 Nm (10 - 80 kg-cm, 8.7 - 69.4 inch lbs.)





- Check ball joint for axial end play.
Tie-rod outer ball joint: 0 mm (0 inch)
Tie-rod inner ball joint: 0 mm (0 inch)
- Check condition of dust cover. If cracked excessively, replace it.

CYLINDER TUBES
Check cylinder tubes for scratches or other damage. Replace if necessary.

Assembly





1. Using a heat gun, heat new teflon rack seal ring to approximately 40°C (104°F). Then place it onto rack.





- Using Tool, compress rack seal ring securely on rack. Always insert the tool from the rack gear side.





2. Insert rack oil seal.
- Place plastic film into rack oil seal to prevent damage by rack teeth.
- Always remove plastic film after rack oil seal is positioned properly.
- Make sure lips of rack oil seal face each other.





3. Install center bushing and rack oil seal with rack assembly.





4. Insert rack oil seal and end cover assembly to rack then tighten end cover assembly.





5. Fasten cylinder end cover assembly to gear housing by staking.





6. Set rack gear in neutral position.
Rack stroke "S": Refer to Alignment; Specifications.





7. Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool.
- Make sure lip of oil seal faces up when installed.





8. Install pinion bearing adjusting shim(s).
- Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.





9. Install pinion seal ring on pinion gear assembly.
- Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly.
- Make sure pinion seal ring is properly settled in valve groove.





10. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip.





11. Install pinion assembly to pinion housing.
Be careful not to damage pinion oil seal.





12. Apply a coat of multi-purpose grease to rear oil seal lip before installing rear housing.





13. Ensure that the rack is centered. Install rear cover cap so that protrusion of rear housing cover is positioned as shown in fig
Be careful not to damage worm ring and oil seal.





14. Install solenoid valve.





15. Install diaphragm spring at retainer.
- Always install retainer, spring washer and diaphragm spring in that order.
- Make sure convex end (painted white) of diaphragm spring faces outward when installing.
16. Install retainer spring and adjusting screw temporarily.

CAUTION: Ensure steering gear spacer is installed with rubber side facing rack.





- Attach lock plate (2) to side rod inner socket (1)
- Insert steering gear spacer (5) to rack (4).
- Apply locking sealant to inner socket threads (3)
- Screw inner socket into rack and (4) tighten to specified torque.
- Stake lock plate at two places.





17. Install steering gear spacer (5) to lock plate (2).





18. Tighten outer socket lock nut.
Tie-rod length "L": Refer to Specifications.





19. Measure rack stroke.
Rack stroke "S": Refer to Specifications.





20. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.





21. Install boot clamps.
- To install, wrap boot clamp around boot groove twice. To tighten clamp, place a screwdriver through both rings. Twist rings 4 to 4-1/2 turns while pulling with a force of approximately 98 N (10 kg, 22 lb.).





- Install boot clamp so that it is to the rear of the vehicle when gear housing is attached to the body. (This will prevent interference with other parts.)





- Twist boot clamp in the direction shown in figure.





- After twisting boot clamp, bend twisted and diagonally so it does not contact boot.