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Home >> Infiniti >> 2004 >> QX56 RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1219 (Power Steering System) >> Power Steering Gear And Linkage >> Disassembly and Assembly >> Assembly

Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Infiniti QX56. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply Genuine NISSAN PSF or equivalent to O-ring. Put an O-ring into rack Teflon® ring.
    CAUTION: Do not reuse O-ring.
  2. Heat rack Teflon® ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack.
    CAUTION: Do not reuse rack Teflon® ring.
    Fig 1: Heating Rack Teflon Ring With Dryer
    G02383736Courtesy of NISSAN MOTOR CO., U.S.A.
  3. To fit rack Teflon® ring on rack, use rack Teflon® ring installation tool from tooth side. Compress rim of ring using Tool.
    1. Tool number: KV48104400 ( - ) 
    Fig 2: Fitting Rack Teflon Ring Onto Rack Using Specified Installation Tool From Tooth Side
    G02383737Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Apply multi-purpose grease to rack oil seal. Insert rack oil seal, then insert rack assembly to gear housing assembly. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS ".
    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: Locating Inner And Outer Rack Oil Seals And End Cover Assembly
    G02383738Courtesy 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: Protecting Inner Rack Oil Seal By Covering Rack Teeth With OHP Sheet
      G02383739Courtesy 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: Positioning Inner Rack Oil Seal and Piston
      G02383740Courtesy 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: Positioning Outer Rack Oil Seal Cover Onto OHP Sheet
      G02383741Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Install end cover assembly to rack, move it to gear housing assembly.
  5. 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 Using Open Head Wrench
    G02383742Courtesy of NISSAN MOTOR CO., U.S.A.
  6. 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: Locating Caulking Point, Gear Housing And End Cover Assembly
    G02383743Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install sub-gear assembly to gear housing assembly.
    CAUTION: Oil seal may be damaged if sub-gear assembly is not installed correctly.
  8. Apply Genuine NISSAN PSF or equivalent to O-ring. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS ". Then install O-ring to rear cover.
    NOTE: Do not reuse O-ring.
  9. Install rear cover to gear housing assembly using Tool.
    1. Tool number: - (J-46213) 
  10. Make sure projection on rear cover cap aligns with mark on gear housing assembly.
  11. Apply thread locking sealant (Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ") 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: Identifying Adjusting Screw
    G02383744Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Rotate pinion ten times through entire rack range to seat gears and to check operation.
  13. 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.
    1. Tool number: ST3127S000 (J25765-A), KV48103400 ( - ) 
    Fig 10: Measuring Pinion Rotating Torque Using Specified Tool
    G02383745Courtesy of NISSAN MOTOR CO., U.S.A.
  14. 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°.
  15. 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.
    1. Pinion rotating torque: 
      1. Around neutral position (within +/-100°) 
    2. Average "A": 
      1. 0.8-2.0 N.m (0.09-0.20 kg-m, 7-17 in-lb) 
    3. Other than above (more than +/-100°) 
    4. Maximum variation "B": 
      1. 2.3 N.m (0.23 kg-m, 20 in-lb) 
    Fig 11: Identifying Pinion Rotating Torque Graph
    G02383746Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Turn pinion to the full left lock position with inner socket to gear housing assembly.
  17. 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: Mounting Dial Gauge To Rack
    G02383747Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 13: Measuring Vertical Movement Of Rack
    G02383748Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install large-diameter side of boot to gear housing assembly.
  19. Install small-diameter side of boot to the mounting groove of inner socket boot.
  20. Install boot clamp to the small-diameter side of boot.
    Fig 14: Identifying Boot Clamps And Boot
    G02383749Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install new boot clamps and crimp securely.
    CAUTION: Do not reuse boot clamps.
    Fig 15: Installing and Tightening Boot Clamps
    G02383750Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install cylinder tubes to gear housing assembly.
  23. Install lock nut and outer socket to inner socket.
  24. 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": 115.2 mm (4.54 in) 
    CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessarily the value given here.
    Fig 16: Identifying Inner Socket Length
    G02383751Courtesy of NISSAN MOTOR CO., U.S.A.
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