NISSAN ALMERA N15 1995 Service Manual

MANUALSTEERING GEARANDLINKAGE (ModelR24N)
Disassembly
SEC. 480

•

SST892BA

@
Tie-rod innersocket

@
Lock plate

@)
Spacer

@
Rack

@
Spacer

@
Lock plate

@
Tie-rod innersocket

@
Tie-rod outersocket

@)

Wave washer

@
Adjusting screw

@
Adjusting locknut

@
Gear housing assembly

@
Boot clamp

@
Boot

@J
Boot band

@
Boot clamp
24'

Do not disassemble.

!ill \
[OJ
78-98 (S-10, 58-72)

~~;:1' \~~~
Dooot d,,,,,,mbt, ~
[OJ
37_"

(3.8 -4.7, 27-34)

~[OJ

49-69(5 -7,36 -51}

~~~m
@ A 39-59 ~
)!l

(4 -6, 29 .43) ""
-=-
q=
5

_~ 0
6
@~~
m

(j];=-@
@~

8
'Donotdisassemble

WIlEi'! "-".
~9
0

13

\

A :
N.m (kg-m, ft-Ib)

CD
Guide chip

@
Rear cover locknut

@
Dustseal

@
Rear cover

@
Pinion bearing

@
Pinion assembly

(j)
Retainer

@
Retaining spring

@
Plain washer

Inspection

BOOT

Check condition ofboot. Ifitis cracked excessively, replaceit.

RACK

Thoroughly examinerackgear. Ifrack gear isdamaged,
cracked orworn, replace.

PINION ASSEMBLY

• Thoroughly examinepiniongear.Ifpinion gearisdamaged,
cracked orworn, replace.
• Check thatallbearings rollfreely. Ensure thatballs, rollers
and races inthe bearing assemblies arenotcracked, pitted
or worn. Replace ifnecessary.

ST-15

MANUALSTEERING GEARANDLINKAGE (ModelR24N)
Inspection (Cont'd)
TIE-ROD OUTERANDINNER SOCKETS

...... A •
Check outerandinner balljoints for
swinging
force"A"and
axial endplay "C".

Refer toSOS CST-35).
Measuring point •
Check outerballjoint forrotating torque"B".

Refer toSOS CST-35).

• Check condition ofdust cover. Ifexcessively cracked,
replace it.

SST057C Assembly andAdjustment
STEERING GEAR

1. Insert rackgear from gearhousing side.
2. Set rack gear inneutral position.

SST518A

GO":,%?
'~
SST6688
3.
Insert pinion assembly, thensetguide chipatneutral posi-
tion asshown infigure. Pinionrackgear should be
held
in
place.

SST815A
4.
Install rearcover withTool andsecure withlocknut.

Tool number: KV48102000
• Before installing rearcover, applylocking sealant to
threaded areas.Donot allow sealant toget into pinion bear-
ing.
• Apply acoat ofmulti-purpose greasetosealing lipsofdust
seal.
CAUTION:
Wrap cellophane tapearound piniongearendwhen installing
dust seal.

5. Insert retainer, spring,plainwasher andwave washer.
Then, install adjusting screw.
• Apply acoat oflocking sealant tothreaded areasofretainer
cover.

Adjusting screw
SST966A

5T-16

SST272A
Pinion
rotating
torque
MANUAL
STEERING GEARANDLINKAGE (ModelR24N)
Assembly andAdjustment (Cant'd)

6. Adjust pinionrotating torqueasfollows:
a. Set gears toneutral position.
b. Loosen locknut.
c. Tighten adjusting screwtoatorque of9.8 N'm (100 kg-cm,
87 in-Ib).
d. Loosen adjusting screwandretighten itto atorque of9.8
N'm (100 kg-cm, 87in-Ib).
e. Loosen adjusting screwwithin60°until specified pinion
torque isobtained. Ensurethatpinion-to-rack playisless
than 0.1mm (0.004 in)when 15N'm (1.5kg-m, 11ft-Ib) torque
is applied topinion.
f. Prevent adjusting nutfrom rotating andtighten locknutto
specified torque39to59 N'm (4to 6kg-m, 29to43 ft-Ib)
holding adjusting screwinplace.
g. While slowly rotating pinioninthe
:f::
100° range fromneu-
tral position, makesureitsrotating torqueiswithin the
specifications.

Within
:f::
100° from theneutral position:
Average rotatingtorque
0.7 -1.2 N'm (7-12 kg-em, 6.1-10.4 in-Ib)
Maximum torquedeviation
0.3 N'm (3kg-em, 2.6in-Ib)
Except forabove measuring range:
Maximum rotatingtorque
1.5 N'm (15kg-em, 13in-Ib)
Maximum forcedeviation
0.5 N'm (5kg-em, 4.3in-Ib)

h. Ifpinion rotating torqueisnot within thespecifications,
readjust.

If pinion rotating torqueisoutside thespecifications after
adjustment hasbeen made, replace retainer spring.
If pinion rotating torqueisstill outofspecifications afterreplac-
ing retainer spring,replace gearassembly.
Average
value

=
(Max. value
+
Min. value) x0.5
Minimum
value Maximum
value
@~~

/) Clinch
l(1)

~@
7.
Install newlockplate. •
• Attach lockplate
@
toside rodinner socket
CD.

• Apply locking sealant toinner socket threads
CID.

Screw innersocket intorack
@
and tighten tospecified
torque.
• Clinch twoplaces oflock plate atrack's
groove.
CAUTION:
To prevent scratching theboot, remove burrsfromlockplate.
SST6748 TIE-ROD ANDBOOT

1. Install bootontie-rod innersocket.
2. Apply locking sealant tothreaded portionofinner socket.
Install tie-rod innersocket torack endtogether withnew
lock plate.
3. Install locknutand outer socket toinner socket. Adjusttie-
rod length "L"and tighten locknut.

Tie-rod length
"L":
Referto50S (ST-35).
Screwed length"
f":
32mm (1.26 in)ormore
SST746A
ST-17

MANUALSTEERING GEARANDLINKAGE (ModelR24N)
Assembly andAdjustment
(Cont'd)

4. Measure rackstroke.

Measure stroke
"S":

Refer toSOS (ST-35).
AST141
5.Before installing boot,coatthecontact surfaces between
boot andtie-rod withgrease.

~==--
SST967A
6.Install bootclamps.
• Toinstall, wrapbootclamp around bootgroove twice.Use
a screwdriver totighten clamps. Twistringsatboth ends 4
to 4-1/2 turns while pulling themwithaforce ofapprox. 98
N (10 kg,22lb).
• Donot cross wireonboot.

AST137
•Bend twisted endofboot clamp asshown atleft. (This will
prevent interference withother parts.)

AST138
ST-18

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)
Removal andInstallation

~ :N.m (kg-m, in-Ib)

[O.J :
N. m (kg-m, ft-Ib)
~~.~

';'-------t"J
29•39 (3.0 •4.0, 22~ ~.'.. ~"'-

:;. --f8\~ ~
d( ~ ~

~ ~~ ~Vehiclefront

[O.J
73-97 (7.4 •9.9, 54•72) ~
&#39;</
SST568C

CD
Lower joint

@
Hole cover

@
Insulator bracket
@

Rear cover cap

@
Gear andlinkage assembly

@
Rack mounting insulator
(J)

Gear housing mounting bracket

@
Cotter pin

CAUTION: •

• The rotation ofthe spiral cable(SRS&#34;Airbag&#34; component
part) islimited.
If
the steering gearmust beremoved, set
the front wheels inthe straight-ahead direction.Donot
rotate thesteering columnwhilethesteering gearis
removed.
• Remove thesteering wheelbefore removing thesteering
lower jointtoavoid damaging theSRS spiral cable.

• Detach tie-rodoutersockets fromknuckle armswithTool.
• When disconnecting steeringshaftlower joint,follow the
procedure shownbelow.
1. Remove nutsforfitting thehole cover.
2. Disconnect thelower jointwhile shifting thehole cover.

ST-19

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)
Removal andInstallation (Cont&#39;d)

• Install pipeconnector.
• Observe specified tightening torquewhentightening high-
pressure andlow-pressure pipeconnectors. Excessive
tightening willdamage threadsofconnector orO-ring.

Connector tighteningtorque:

CD
Low-pressure side
27 -39 N&#39;m (2.8-4.0 kg-m, 20-29 ft-Ib)
~ High-pressure side
15 -25 N&#39;m (1.5-2.5 kg-m, 11-18 ft-Ib)

• The O-ring inlow-pressure pipeconnector islarger than
that inhigh-pressure connector.Takecaretoinstall the
proper O-ring.
• Initially, tightennutontie-rod outersocket andknuckle arm
to 29 to39 N&#39;m (3to 4kg-m, 22to29 ft-Ib). Thentighten fur-
ther toalign nutgroove withfirstpinhole sothat cotter pin
can beinstalled.

CAUTION:
Tightening torquemustnotexceed 49N&#39;m (5kg-m, 36ft-Ib).

• Before removing lowerjointfrom gear, setgear inneutral
(wheels instraight-ahead position).Afterremoving lower
joint, putmatching markonpinion shaftandpinion housing
to record neutral position.
• Toinstall, setleftand right dustboots toequal deflection.
Attach lowerjointbyaligning matching marksofpinion
shaft andpinion ~ousing.
• Tighten gearhousing mounting bracketboltsinthe order
shown.

o
@

~
&#39;--v---&#39; ~

Temporary ..
tightening SecuretIghtening

SST6778
ST-20

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)

•

~ :N.m (kg-m. ft-lb)

f] :
Lubrication points
(With automatic
transmission fluid
&#34;DEXRON&#39;u&#34; type
or equivalent)
I

@~~~~
~~(SRandCD
~ ~~ enginemodels)

8
~78. 98

(8.0 •10.0,
58•72)

GA engine model
~ 37•46 (3.8 •4.7, 27.34)
CD and SRengine models

M
78.98
(8.0 •
10.0, 58•72)

(SR
,,&#39;CD,&#34;,,&#34;,
m_&#34;&#39;7
~\Il~

m~
@,
~16.21

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r
<V~!ilh,~&#39;1
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~20.
26
(2.0 •2.7, 14•20)
SEC.
492

@)(]~\-
.~
~&#39;
r
L
~to:J59&#39; 74
20~
(6.0 •
7.5, 43.54)

_~ @Donotdisas~smble.
0

to:J 29•39

{3.0 .4.0,22. &#34;~~

SST506CA

Pinion oilseal
Lock nut
Adjusting screw
Spring
Spring disc

G)

Rear cover cap

@
Rear housing assembly

@
Pinion sealring

@
Pinion assembly

CID
O-ring

@
Shim

(J)

@
@

@)

@ @

Washer

@
Spring seat

@
Retainer

@
Gear housing

@
Center bushing

@
Rack oilseal

@
Rack assembly

@
Rack sealring

@)
O-ring

@
Rack oilseal
@

Endcover assembly

@
Boot clamp

@
Dust boot

@
Boot band

@l
Steering gearspacer

@
Lock plate

@
Tie-rod innersocket

@
Tie-rod outersocket

@
Cotter pin

@
Gear housing tube

ST-21

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)
Disassembly

1. Prior todisassembling, measurepinionrotating torque.
Record thepinion rotating torqueasareference.

• Before measuring, disconnectgearhousing tubeanddrain
fluid.
• Use softjaws when holding steering gearhousing. Handle
gear housing carefully, asitis made ofaluminum. Donot
grip cylinder inavise.

2. Remove piniongear.

Be careful nottodamage piniongearwhen removing pinion
seal ring.

3. Remove tie-rodoutersockets andboots.
4. Loosen tie-rodinnersocket byprying upstaked portion, and
remove socket.
5. Remove retainer.
6. Remove pinionassembly.
7. Use a2to 2.5 mm (0.079 to0.098 in)diameter drilltocom-
pletely remove stakedportion ofgear housing end.
8. Remove endcover assembly withasuitable tool.
9. Draw outrack assembly.
10. Remove rackseal ring.
• Using aheat gun,heat racksealtoapproximately 40°C
(104°F).
• Remove racksealring.

Be careful nottodamage rack.

11. Remove centerbushing andrack oilseal using tape
wrapped socketandextension bar.

Do not scratch innersurfaces ofpinion housing .

.. !tension bar
29 mm socket

SST472AInspection

Thoroughly cleanallparts incleaning solventorautomatic
transmission fluid&#39;&#39;DEXRON™,, typeorequivalent. Blowdry
with compressed air,ifavailable.

BOOT

• Check condition ofboot. Ifcracked excessively, replaceit.
• Check bootsforaccumulation ofpower steering fluid.

RACK

Thoroughly examinerackgear. Ifdamaged, crackedorworn,
replace it.

ST-22

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)
Inspection (Cont&#39;d)
PINION ASSEMBLY

• Thoroughly examinepiniongear.Ifpinion gearisdamaged,
cracked orworn, replace it.
• Check thatallbearings rollfreely. Ensure thatballs, rollers
and races arenotcracked, pittedorworn. Replace ifnec-
essary.

GEAR HOUSING CYLINDER

Check gearhousing cylinder boreforscratches orother dam-
age. Replace ifnecessary.

SST083B
•

2.
Using Tool,compress rackseal ringsecurely ontorack.

Always insertToolfrom therack gear side.
TIE-ROD
OUTERANDINNER SOCKETS

• Check balljoints forswinging force.

Tie-rod outerandinner ball
joints
swinging force
&#34;A&#34;:

Refer toSOS (ST-35).

• Check balljoint forrotating torque.

Tie-rod outerballjoint rotating torque
&#34;B&#34;:

Refer to50S (ST-35).

• Check balljoints foraxial endplay.

Tie-rod outerandinner balljoints axialendplay
&#34;e&#34;:

Refer to50S (ST-35).

• Check condition ofdust cover. Ifcracked excessively,
replace outertie-rod.

Assembly

1. Using aheat gun,heat newteflon rackseal ringtoapprox-
imately 40°C(104°F). Thenplace
it
onto rack.

Us

Rack sealring
Inner
ball joint
+

Measuring pOin;~~
+
C

/&#39;

~R&#34;k ,.. I
&#34;&#34;9

Position and
secure seal.

SST885BA
c--.~
~

Film

Rack oilseal 3.
Insert newrack oilseal.

• Place plastic filmintorack oilseal toprevent damage by
rack teeth.
• Donot forget toremove plasticfilmafter rackoilseal is
positioned properly.
• Make surelipsofrack oilseal face each other.
SST201A ST-23

POWERSTEERING GEARANDLINKAGE (ModelPR24AC)
Assembly (Conl&#39;d)

4. Install center bushing andrack oilseal with rackassembly.

SST830A
5.Insert rackoilseal andendcover assembly torack. Then
tighten endcover assembly.

End cover assembly
SST321B

2-3mm
(0.08 •0.12 In)

SST073B
SST086BA
6.
Fasten endcover assembly togear housing bystaking.
7. Set rack gear inneutral position.

Rack stroke
&#34;5&#34;:

Refer to50S (ST-35).

Suitable tool
Oil seal
SST381A
8.
Coat seallipofnew pinion oilseal with multi-purpose
grease. Installitinto pinion housing ofgear withasuitable
tool.

Make surelipofoil seal faces upwhen installed.

ST-24