Steering Gear Disassembly

1. Remove the steering gear from the vehicle. For Maxima models, use the R&R procedures in Technical Bulletin ST86-003 (TS86-067).

2. Allow all the power steering fluid to drain from the system while the gear is being rebuilt. Drain as much fluid from the gear as possible by rotating the pinion from lock to lock while holding the pinion housing over a drain pan. Also drain the fluid in each boot into the drain pan by disconnecting the breather tube, removing each boot clamp and pulling the boots away from the steering gear.

FIGURE 1:

3. Install the steering gear on Power Steering Stand J28817 (Figure 1). Clamp the stand in a vise at an angle, and install the gear so the housing plug is facing you, the pinion is facing away from you, and the retainer is facing down. If this tool is not available, DO NOT clamp the middle of the cylinder assembly in a vise. This will distort the cylinder assembly and cause the rack piston to bind or leak. Instead, clamp the pinion housing in a vise with soft jaws.

FIGURE 2:

4. Remove the long cylinder tube and breather hose. Leave both pieces clipped together. Remove the housing plug (24 mm) and self-lock nut (17 mm) (Figure 2).

FIGURE 3:

FIGURE 4:

5. Flatten both lock plates (Figure 3), and disconnect the inner tie rod sockets from the rack (Figure 4). There may be a rack spacer at each end of the rack. Remove and save these spacers.
6. Inspect the boots for cracks, splits or other damage. If the boots are not damaged, they can be cleaned and used again. If they are damaged, they must be replaced. If the boots are damaged, separate the inner and outer tie rod sockets, and remove and discard the boots. Save the small boot clamps (O-rings) to use with the new boots.

FIGURE 5:

7. Remove both retainer cover bolts (12 mm), the cover and gasket, spring, spring seat (if used), and retainer (Figure 5).

FIGURE 6:

8. Remove the rear housing cover cap and snap ring (Figure 6). Carefully tap on the lock nut end of the pinion shaft with a soft-faced hammer to drive the pinion assembly and rear housing cover out of the pinion housing. The large pinion ball bearing may come out with the pinion, or may remain in the pinion housing. Remove the O-ring from the rear housing cover and press out the old seal with a suitable tool.

FIGURE 7:

9. The end cover assembly on this style steering gear screws into the end of the cylinder assembly. It is staked into position at the factory to prevent loosening. This staked area must be drilled out before the end cover can be removed (Figure 7).
10. Temporarily clamp the end of the cylinder assembly in a vise with soft jaws. Position the steering gear so the stake mark is accessible, and the jaws are squeezing the flats on the cylinder assembly. Leave the Power Steering Stand attached to the pinion housing.

FIGURE 8:

11. Cover the exposed end of the rack with tape or plastic to prevent damage from metal chips. Use a 3/16" drill. Drill through the staked area into the end cover assembly to a depth of about 3/16" (Figure 8). Smooth the rough edges around the hole with a file.

CAUTION: Drill completely through the cylinder assembly and into the end cover assembly. You must remove all the deformed metal to prevent damage to the cylinder assembly threads when removing the end cover assembly.

FIGURE 9:

12. Use Cylinder End Cover Socket J28822 to remove the cylinder end cover assembly (Figure 9). Remove the rack, backup washer, and rack oil seal by tapping on the pinion housing end of the rack. If necessary, use a hammer and large punch to drive out the rack.
Do not damage the internal threads on the pinion end of the rack.

FIGURE 10:

13. Reposition the steering gear by clamping the Power Steering Stand in the vise as described in step 3. Apply match marks to the cylinder assembly and pinion housing (Figure 10).

FIGURE 11:

14. Use Cylinder Lock Nut Wrench J35995 to loosen the pinion housing lock nut (Figure 11). Remove the cylinder assembly and inner tube from the pinion housing.

FIGURE 12:

FIGURE 13:

15. Remove the old oil seal and backup collar from the inner tube. Use Pinion Bearing Race Remover J25749-A (Figure 12) or a socket and extension (Figure 13).

FIGURE 14:

16. Remove the plastic inner tube collar, snap ring, and large washer from the inner tube (Figure 14). Use Snap Ring Pliers With Parallel Opening Jaws J8059 and be careful to not scratch the outside of the inner tube. This is a sealing surface.

FIGURE 15:

FIGURE 16:

17. Use a punch to gently tap the pinion bearings and old pinion housing oil seal out of the pinion housing (Figures 15 and 16).
18. The following parts will be replaced with new parts from the Rebuild Seal Kit. Use the old parts to help identify the new parts in the seal kit, then discard them.

- snap ring for rear housing cover
- oil seal in rear housing cover
- O-ring on rear housing cover
- pinion housing oil seal
- self-lock nut
- housing plug
- retainer cover gasket
- rack oil seal from inner tube
- rack oil seal next to end cover assembly
- O-ring on cylinder assembly
- O-ring inside pinion housing (mates with inner tube)
- 2 lock plates
- wire-type boot clamps