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Home >> Infiniti >> 2006 >> M35 Base >> Repair and Diagnosis >> Steering >> Power Steering >> Power Steering System >> Power Steering Gear >> Disassembly and Assembly >> Assembly
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Disassembly and Assembly: Assembly

  1. Apply power steering fluid to O-ring. Put an O-ring into rack Teflon ring.
  2. Heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack assembly.
    Fig 1: Heating Rack Teflon Ring With Dryer
    G04144850Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the Teflon ring correcting tool [SST] from tooth side of rack to fit rack Teflon ring on rack. Compress the ring with tool.
    Fig 2: Identifying Teflon Ring Correcting Tool
    G04144851Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Apply multi-purpose grease to rack oil seal. And install rack oil seal in the following procedure. Then assemble rack assembly to gear housing assembly.
    Fig 3: Identifying Rack Oil Seal
    G04144852Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Install rack oil seal in a direction so that the lip of inner oil seal and the lip of outer oil seal face each other.
    • Do not damage retainer sliding surface by rack assembly. Replace gear housing assembly if damaged.
    • Do not damage gear housing assembly inner wall by rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage.
    1. Wrap an OHP sheet [approximately 70 mm (2.76 in) x 100 mm (3.94 in)]. Around rack assembly teeth to avoid damaging rack oil seal (inner). Install rack oil seal over sheet. Then, pull oil seal along with OHP sheet until they pass rack assembly teeth, and remove OHP sheet.
      Fig 4: Wrapping OHP Sheet
      G04144853Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Insert rack oil seal (inner) into rack assembly piston (rack Teflon ring).
    3. Push retainer to adjusting screw side by hand, and move the rack assembly inside the gear housing assembly so that the rack oil seal (inner) can be pressed against the gear housing assembly.
      Fig 5: Inserting Rack Oil Seal Into Rack Assembly Piston
      G04144854Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Wrap an OHP sheet [approximately 70 mm (2.76 in) x 100 mm (3.94 in)]. Around the edge to avoid damaging rack oil seal (outer). Install rack oil seal over sheet. Then, pull oil seal along with OHP sheet until they pass rack edge, and remove OHP sheet.
    5. Install end cover assembly to rack edge, and move rack oil seal (outer) until it contacts with gear housing assembly.
      Fig 6: Wrapping OHP Sheet
      G04144855Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Tighten end cover assembly to specified torque using a 36 mm (1.42 in) open head (suitable tool).
    CAUTION: Do not damage rack assembly. Replace it if damaged because it may cause fluid leakage.
    Fig 7: Tightening End Cover Assembly
    G04144856Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Crimp gear housing assembly at one point using a punch as shown in Fig 8 so as to prevent end cover assembly from getting loose after tightening end cover assembly.
  7. Apply power steering fluid to O-ring, and then install O-ring to gear housing assembly.
  8. Install gear-sub assembly to gear housing assembly.
  9. Install EPS solenoid valve to gear-sub assembly.
    Fig 8: Identifying Gear-Sub Assembly And Gear Housing Assembly
    G04144857Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Decide on the neutral position for the rack.
    RACK STROKE

    Drive type 2WD AWD
    Rack stroke "L" 68.5 mm (2.697 in) 67.0 mm (2.638 in)
    Fig 9: Identifying Rack Position
    G04144858Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install rear cover cap to gear sub-assembly.
    CAUTION: Make sure that the projection of rear cover cap is aligned with the marking position of gear housing assembly.
  12. Apply Genuine Liquid Gasket, Three Bound 1111B or equivalent to the thread (2 turns thread), and then screw in the adjusting screw until it reaches height "H" from gear housing assembly measured before disassembling.
  13. Move rack assembly 10 strokes throughout the full stroke so that the parts can fit with each other.
    Fig 10: Identifying Rack Assembly Moving Position
    G04144859Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Measure pinion rotating torque within +/-180° of neutral position of the rack assembly using the preload gauge [SST] and preload adapter [SST]. Stop the gear at the point where highest torque is read.
  15. Loosen adjusting screw and retighten to 5.4 N.m (0.55 kg-m, 48 in-lb), and then loosen by 20 to 40°.
    Fig 11: Measuring Pinion Rotating Torque
    G04144860Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Measure pinion rotating torque using the preload adapter [SST] and preload gauge [SST] to make sure that the measured value is within the standard. Readjust if the value is outside the standard. Replace steering gear assembly if the value is outside the standard after readjusting or adjusting screw rotating torque is 5 N.m (0.51 kg-m, 44 in-lb) or less.
    Fig 12: Measuring Pinion Rotating Torque Using Preload Adapter
    G04144861Courtesy of NISSAN MOTOR CO., U.S.A.
    PINION ROTATING TORQUE STANDARD

    Pinion rotating torque standard 2WD AWD
    Around neutral position (within+/-100°)
    Average A    		 1.95 - 2.58 N.m
    (0.20 - 0.26 kg-m, 18 - 22 in-lb)    		 2.27 - 3.05 N.m
    (0.24 - 0.31 kg-m, 20 - 26 in-lb)
    Maximum variation B 0.98 N.m (0.10 kg-m, 9.0 in-lb)
  17. Apply Genuine Liquid Gasket, Three Bound 1111B or equivalent to inner socket and turn pinion fully to left with inner socket installed to gear housing assembly.
  18. Set dial gauge as shown in Fig 13 . Measure vertical movement of rack assembly when pinion is turned clockwise with torque of 19.6 N.m (2.0 kg-m, 14 ft-lb). Readjust adjusting screw angle if the measured value is outside the standard. Replace steering gear assembly if the measured value is still outside the standard or adjusting screw rotating torque is 5 N.m (0.51 kg-m, 44 in-lb) or less.
    Fig 13: Measuring Vertical Movement Of Rack Assembly
    G04144862Courtesy of NISSAN MOTOR CO., U.S.A.
    MEASURING POINT

    Measuring point  Rack axial direction  5 mm (0.20 in) from housing end surface
    Rack radial direction  Axial direction of the adjusting screw
    Vertical movement  0.265 mm (0.0104 in)
  19. Install large end of boot to gear housing assembly.
  20. Install small end of boot to inner socket boot mounting groove.
  21. Install boot clamp to boot small end.
    Fig 14: Identifying Boot Clamps
    G04144863Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install large side of boot clamp.
    • Tighten large side of boot with boot clamp (stainless wire).

      Wire length "L": 370 mm (14.57 in) 

    • Wrap clamp around boot groove for two turns. Insert a flatbladed screwdriver in loops on both ends of wire. Twist 4 to 4.5 turns while pulling them with force of approximately 98 N (10 kg, 22 lb).
      Fig 15: Identifying Large Side Of Boot Clamp
      G04144864Courtesy of NISSAN MOTOR CO., U.S.A.
    • Twist boot clamp as shown. Pay attention to relationship between winding and twisting directions.
      Fig 16: Twisting Boot Clamp
      G04144865Courtesy of NISSAN MOTOR CO., U.S.A.
    • Twisted point of clamp is in the opposite side of adjusting screw (1) as shown in Fig 17 (to prevent contact with other parts).
      Fig 17: Identifying Twisted Point Of Clamp
      G04144866Courtesy of NISSAN MOTOR CO., U.S.A.
    • Bent cut end of the wire toward rack axial as shown in Fig 18 after twisting the wire 4 to 4.5 turns so that cut end does not contact with boot.
      CAUTION: Keep gap from cylinder tube 5 mm (0.20 in) or more.
  23. Install cylinder tubes to gear housing assembly.
    Fig 18: Bending Cut End Of Wire Toward Rack Axial
    G04144867Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Adjust inner socket to standard length "L", and then tighten lock nut to the specified torque. Refer to , "COMPONENTS ".

    Check length of inner socket "L" again after tightening lock nut.

    Make sure that the length is the standard.

    INNER SOCKET LENGTH

    Drive type 2WD AWD
    Inner socket length "L" 63.9 mm (2.516 in) 55.2 mm (2.173 in)
    Fig 19: Identifying Tie Rod Components And Rod Length Measurement Area
    G04076779Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Adjust toe-in after this procedure. Length achieved after toe-in adjustment is not necessary the above value.
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