boot NISSAN X-TRAIL 2003 Electronic Owner's Manual

PS-12
POWER STEERING GEAR AND LINKAGE
POWER STEERING GEAR AND LINKAGE
PFP:49001
Removal and InstallationEGS0004I
REMOVAL
1. Remove cotter pin, and loosen mounting nut. Remove tie rod from steering knuckle with a pitman arm
puller.
CAUTION:
lBe careful not to damage dust boot at ball joint of tie rod.
lBefore using pitman arm puller (multi-purpose tool), loosely tighten nut for temporary holding.
2. Mark lower joint and steering gear with paint for easy installation. Remove pinch bolt from gear side of
lower joint.
3. Remove high pressure-side tube and low pressure-side hose of hydraulic piping from steering gear.
4. Remove mounting nuts on upper portion of stabilizer connecting rod and stabilizer clamp mounting bolts.
Move stabilizer toward vehicle front.
5. Remove steering gear assembly mounting bolts and nuts. Remove power steering tube bracket and
steering gear assembly from suspension member.
6. Tilt steering gear to prevent any contact with other parts. Then remove it from right side of vehicle.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.
lAfter installation, bleed air. Refer toPS-5, "Bleeding Hydraulic System".
lRemove mounting bolt and nut from upper portion of lower joint. This will facilitate installation of lower joint
to steering gear. Then slide lower joint in place.
lCheck lower slit of lower joint is engaged with projection on rear
cover cap. Install pinch bolt for lower portion of lower joint.
Check steering gear is in straight-ahead position. Also check
rear cover is in position shown in figure. Then install lower joint
to steering gear.
SGIA0009E
1 Power steering gear assembly 2 Power steering tube bracket 3 Cotter pin
SGIA0105E

POWER STEERING GEAR AND LINKAGE
PS-15
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Disassembly and AssemblyEGS0004K
DISASSEMBLY
1. To disassemble and assemble power steering gear, fix steering
gear mount flange in a vise with copper plates.
CAUTION:
lClean steering gear with kerosene. Be careful to avoid
splashing or applying any kerosene over connector of
discharge port or return port.
lAlways replace O-rings, oil seals, and copper washes
with new ones.
2. Loosen and remove adjusting screws and lock nuts.
3. Remove rear housing mounting bolts to remove gear sub
assembly.
CAUTION:
Do not disassemble rear housing and pinion gear assem-
bly.
4. Remove tie rod outer socket and boot.
5. Remove spacer ring on lock plate. Move it to rack side to expose
crimping of lock plate.
CAUTION:
lDo not reuse boot, spacer ring, and lock plate.
lWhen removing boot, do not damage boot mounting
grooves by tool. If it damaged, it may cause oil leak.
Replace tie rod inner socket and gear housing assembly.
lWhen removing lock plate from rack, avoid damaging
surface of rack. If damaged, rack assembly must be
replaced. Otherwise, oil leaks will result.
6. Raise crimping areas (2) (A) of lock plate. Loosen inner socket and remove from rack.
1 Gear housing assembly 2 Cylinder tube 3 Rear cover cap
4 Rear housing assembly 5 Pinion seal ring 6 Pinion assembly
7 O ring 8 Lock nut 9 Adjusting screw
10 Spring 11 Retainer 12 Center bushing
13 Rack oil seal (inner) 14 Rack oil seal (outer) 15 Spacer
16 End cover assembly 17 Boot clamp 18 Dust boot
19 Boot band 20 Rack 21 Spacer ring
22 Rack seal ring 23 O-ring 24 Lock plate
25 Inner socket 26 Outer socket
SGIA0056E
SGIA0018E
SGIA0019E

PS-16
POWER STEERING GEAR AND LINKAGE
7. Drill out punch crimping area on cylinder outer rim with a 3-mm
(0.12in) drill bit.{Drill for approx. 1.5 mm (0.059in) in depth.}
8. Remove end cover with a 36-mm (1.42 in) open head.
CAUTION:
When removing, avoid damaging surface of rack. If dam-
aged, rack assembly must be replaced. Otherwise, oil leaks
will result.
9. Pull rack assembly with rack seal out of gear housing assembly.
CAUTION:
When pulling out rack assembly, do not damage cylinder
inner wall. If it damaged, it may cause oil leak. Replace gear
housing assembly.
10. Heat Teflon ring to approx. 40°C (104°F) with a hot air blower Remove it and O-ring from rack. Be careful
not to damage rack.
11. Use a taped 29-mm socket and an extension bar. Push out and
remove center bushing and rack oil seal together from pinion
housing.
CAUTION:
lBe careful not to damage pinion housing and cylinder
inner wall.
lIf damaged, gear housing assembly must be replaced.
Otherwise, oil leaks will result.
PINION GEAR ROTATION TORQUE ADJUSTMENT
INSPECTION AFTER DISASSEMBLY
Boot
Check boot for tear, wrinkle, and deformation. Replace it, if necessary.
Rack
Check rack gear for damage and wear. Replace it, if necessary.
Gear subassembly
lCheck pinion gear for damage and wear, and replace if necessary.
lCheck bearing while rotating it. Replace bearing if bearing ball race was dent, worn, or damaged.
Gear housing cylinder
Check gear housing cylinder for damage and scratch (inner wall). Replace it, if necessary.
Tie rod ball joint
1. Tensile force
STC0013D
SST052C
SST472A

POWER STEERING GEAR AND LINKAGE
PS-21
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23. Using a preload gauge, measure rotational torque of pinion gear.
Check that reading is within range specified. If reading is outside
specification, readjust rack. If reading is still outside specifica-
tion, replace power steering gear.
24. With tie rod gear installed to gear assembly, turn pinion gear
fully to left.
25. Set dial gauge as shown in figure. Measure vertical movement
of rack when pinion is turned counterclockwise with torque of 4.9
N·m (0.5 kg·m,43in·lb). Check reading is within range specified.
If reading is outside of specification, readjust rack. If reading is
still outside of specification, replace power steering gear.
26. Position boot band on large-diameter side before installing it.
27. Apply multi-purpose grease to both large- and small- diameter
sides.
28. Install small-diameter side of boot to inner socket boot mounting
groove.
29. Install boot band to small-diameter side of boot.
30. Install boot band.
a. Tighten large-diameter side of RH/LH boot with boot clamp
(stainless wire).
b. Wrap clamp around boot groove for two turns. Insert screwdriv-
ers in loops on both ends of wire. Twist 4 to 4.5 turns while pull-
ing them with force of approx. 98 N (10 kg,22.1 lb).Rotational torque
of pinion gear: Around neutral position
{within±11.5 mm (0.453 in)}
Average A : 167 - 225 N·m (17 - 23
kg·m,123-166 ft·lb)
Maximum varia-
tion B: 98 N·m (10 kg·m,72 ft·lb)
Other than above
Average A : 294 N·m (30 kg·m,217 ft·lb)
Maximum varia-
tion B: 147 N·m (15 kg·m,108 ft·lb)
SGIA0098E
Specification : 0.08 mm (0.0031 in) or less
SGIA0099E
Measuring point in shown in figure at right.Rack axle direction 5 mm from housing vertical surface
Rack radial direction Direction of adjusting screw
SGIA0024E
Wire length (L) : 370 mm (14.57 in)
SST097B

PS-22
POWER STEERING GEAR AND LINKAGE
c. Twist boot clamp as shown. Pay attention to relationship
between winding and twisting directions.
d. Twisted point should face front of vehicle with gear installed on
vehicle (to prevent interference with other parts).
e. 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.
31. Connect lock nut and outer socket to inner socket. Temporarily
tighten lock nut until length of tie rod is within specification.
CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily value given
here.
SST440A
SGIA0025E
STC0124D
Tie rod length (L) : 169.67 mm (6.68 in)
STC0125D

REAR DRIVE SHAFT
RAX-9
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REAR DRIVE SHAFTPFP:39600
Removal and InstallationEDS000FL
REMOVAL
1. Remove rear axle. Refer toRAX-6, "REMOVAL".
NOTE:
In order to remove the rear drive shaft assembly, the rear axle is removed. At this time it is recommended
that front and rear parallel links on axle side be loosened (not removed). This will facilitate wheel align-
ment inspection and adjustment which are carried out later.
2. As shown in the figure, use a wheel wrench or similar tool to
remove drive shaft from final drive.
INSPECTION AFTER REMOVAL
lMove the joint in the up/down, left/right, and axial directions. Check for any rough movement or significant
looseness.
lCheck boot for cracks or other damage, and also for grease leakage.
INSTALLATION
1. In order to prevent damage to final drive side oil seal, first fit a
protector onto oil seal before inserting drive shaft. Slide drive
shaft into slide joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circular clip is securely fastened.
2. Install rear axle. Refer toRAX-7, "
INSTALLATION"
SDIA0604E
DSR0015D
DSR0010D

RAX-10
REAR DRIVE SHAFT
Disassembly and Assembly
EDS000FM
DISASSEMBLY
Final Drive Side
1. Remove boot bands.
2. Fix shaft to bench vise.
CAUTION:
When fixing shaft to bench vise, be sure to protect it with a copper or aluminum sheet.
3. Make alignment marks on shaft and spider assembly.
CAUTION:
Use paint or similar substance for alignment marks. Do not
scratch the surface.
4. Remove snap ring. Remove spider assembly from shaft.
5. Remove boot from shaft.
Wheel Side
1. As shown in the figure, use a bearing replacer and puller to
remove sensor rotor from drive shaft.
2. Fix shaft to bench vise.
CAUTION:
When fixing shaft to bench vise, be sure to protect it with a
copper or aluminum sheet.
3. Remove boot bands. Remove boot from joint sub-assembly.
SDIA0605E
1 Sensor rotor 2 Joint sub assembly 3 Circular clip
4 Boot bands 5 Boot 6 Shaft
7 Boot 8 Boot bands 9 Spider assembly
10 Snap ring 11 Housing (Slide joint) 12 Circular clip
SDIA0594E
SDIA0595E

REAR DRIVE SHAFT
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4. Screw a drive shaft puller 30 mm (1.18 in) or more into threaded
part of joint sub-assembly. Pull joint sub-assembly out of shaft.
CAUTION:
If joint sub assembly cannot be removed after five or more
unsuccessful attempts, replace the entire drive shaft
assembly.
5. Remove boot from shaft.
6. Remove circular clip from shaft.
7. Remove old grease.
INSPECTION AFTER DISASSEMBLY
Shaft
lReplace shaft if there is any runout, cracking, or other damage.
Boot and Boot Bands
lIf boot is ruptured, replace it.
lOnce boot bands are removed, they must be replaced with new ones.
Joint Sub-Assembly (Fixed Joint)
lCheck that there is no rough rotation or unusual axial looseness.
lCheck that there is no foreign material inside joint.
CAUTION:
If there are any irregular conditions of joint assembly components, replace the entire joint assem-
bly.
Joint Assembly (Slide Joint)
lIf there is scratching or wear of housing roller contact surface or spider roller contact surface, replace
housing and spider assemblies.
lIf there is circumferential looseness or rough rotation of spider roller, replace spider assembly.
lAs shown in the figure, the spider roller has a stamped number
which corresponds to a part number. Select a suitable replace-
ment part with the same stamp number from the table below.
lIf there are any irregular conditions of joint assembly compo-
nents, replace the entire joint assembly.
lFor housing replacement, spider assembly and joint assembly
are a set.
Housing (Sliding Joint)
lCheck that there is no damage or unusual wear of ball rolling surface.
lCheck that there is no damage to shaft screws.
lCheck that there is no deformation of boot installation parts.
Ball Gauge
lCheck that there is no damage or other irregular conditions of sliding surface.
SDIA0606E
Stamped No. Part No. Model
00 39720 2U610
T58C 01 39720 2U611
02 39720 2U612
03 39720 2U613
04 39720 2U614
05 39720 2U615
06 39720 2U616
SDIA0596E

RAX-12
REAR DRIVE SHAFT
Steel Ball
lCheck that there is no damage or unusual wear.
Inner Case
lCheck that there is no damage or other irregular conditions of ball rolling surface.
lCheck that there is no damage to serrated part.
ASSEMBLY
Final Drive Side
1. Wind serrated part of drive shaft with tape. Install boot band and
boot to shaft. Be careful not to damage boot.
CAUTION:
Discard the old boot band and boot; replace with new ones.
2. Remove protective tape wound around serrated part of shaft.
3. Line up alignment marks which were made when spider assem-
bly was removed. Install spider assembly, with serration chamfer
facing drive shaft.
4. Secure spider assembly with snap ring.
CAUTION:
Discard the old snap ring; replace with a new one.
5. Apply grease (Nissan genuine grease or equivalent) to spider
assembly and sliding surface.
6. Install housing to spider assembly. Add remaining grease (Nis-
san genuine grease or equivalent) up to the amount listed
below.
7. Install boot securely into grooves (indicated by * marks) shown
in the figure.
CAUTION:
If there is grease on boot mounting surfaces (indicated by *
marks) of joint, boot may come off. Remove all grease from
surfaces.
SDIA0597E
Grease amount : 40 - 50 g (1.41 - 1.77 oz)
SDIA0598E
SDIA0599E

REAR DRIVE SHAFT
RAX-13
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8. Check that boot installation length “L” is the length indicated
below. Insert a flat-bladed screwdriver or similar tool into smaller
side of boot. Remove air from boot to prevent boot deformation.
CAUTION:
lBoot may break if boot installation length is less than
standard value.
lBe careful that screwdriver tip does not contact inside
surface of boot.
9. Secure big and small ends of boot with new boot bands as
shown in figure.
CAUTION:
Rotate housing and check that boot installation position
does not change. If position changes, reinstall boot bands.
Wheel Side
1. Use a drift to press-fit sensor rotor into joint sub-assembly.
CAUTION:
Discard the old sensor rotor; replace with a new one.
2. Wind serrated part of drive shaft with tape. Install boot band and
boot to shaft. Be careful not to damage boot.
CAUTION:
Discard the old boot band and boot; replace with new ones.
3. Remove protective tape wound around serrated part of shaft.Boot installation length
: 78.6 - 80.6 mm (3.094 - 3.173 in)
SDIA0600E
SFA395
SDIA0602E
SDIA0597E