CLASS 14,5 SERVICE BULLETIN REPS SAA nissan Forkitt Corporation FORKLIFT “°% Prospect Street; Marengo, IL 60152 SB 2006-247 MECHANICAL Date: May 19, 2006 To: AllDealer Principals All Service Managers From: Customer Quality Department - Service Subject: Steering Washer for Horn Plunger Wear Applied Model: P01/PO02 Due to the number of inquiries we have received in reference to horn plungers wearing excessively or unevenly, a steer washer service part has been established. This washer increases the contact area of the horn plunger from a diameter of 39mm to 48mm. The part number for this Steer Washer is 4881 9-2KOOE, this washer is installed by removing the steering wheel, placing this washer, undercut side down, over the steer shaft and pressing it on to the existing hom plunger contact plate. 48819-2KO0E Steering Washer Steer Shaft Current Horn Plunger Contact Ring Bushing Assembly Removal and Installation of the steering wheel can be located in the P01/P02 Service Manual in the “ST” section. Please insert this bulletin in this section of your service manual. Should you have any questions, please contact the Customer Quality Department at 815-568-0061 or at Service@nfona.com. Best Regards, Nissan Forklift Corporation ee buun oot obo contved a Manager, Service-Specialists bavi fr any cine epi INE, unos ere sated CUSTOMER SATISFACTION DEPARTMENT Phone Number: (815) 568-0061 Fax Number: (815) 568-0186CLASS 1,4,5 SERVICE BULLETIN EAU NISSAN Forklift Corporation, North America FORKLIFT «21° 8ott Prospect Street; Marengo, 1. 60152 SB 97-002 MECHANICAL Date: February 17, 1997 To: All Dealer Principals and Service Managers From: Customer Satisfaction Technical Publications Department Subject: Dimension Changes for the Steering Adjustment Model: PO1/P02 Cushion Starting Chassis Number: All Cushion PO1/P02's Manufactured in Marengo, IL Please note that pages ST-32 & ST-38, figures L1, L2 and L3, in your current Service Manual are the measurements for the Pneumatic Tired Units Only. The following chart is for the Cushion Tired Units Only: Model Wt © WheelBase LI Page ST-32 L2 Page ST-32 L3 Page ST-38 Pol 3000 Al 1275-129.Smm —56-59mm _854.6-857.6mm 3500 (5.02-5.10")(2.20-2.32") (33.45-33.75") P02 4000» Standard. =—«127.5-129.5mm $6-59mm_——_925.4-928.4mm 5000 (Short) (5.02-5.10") (2.20-2.32")_(36.43-36.55") poz $000,» Long 127.5-129.5mm —$6-59mm_—_1023.5-1026.5mm 6000 (5.02-5.10")(2.20-2.32") (40.30-40.41" Sincerely, Nissan Forklift Corporation Customer Satisfaction Technical Publications Department Please insure that this important information is given to all your Service Personnel. Insert a copy of this bulletin into the ST Section of your P01/P02 Service Manual. Phone Number: (815) 568-0061 Fax Number: (815) 568-0187 CUSTOMER SATISFACTION DEPARTMENTSTEERING SYSTEM SECTION S T CONTENTS SERVICE DATA AND SPECIFICATIONS. 2 General Specifications. 2 Inspection and Adjustment... 2 Tightening Torque. 3 ‘TROUBLE DIAGNOSES AND CORRECTIONS... 4 PRECAUTIONS AND PREPARATION 6 Precautions... 6 Special Service Tools 6 STEERING SYSTEM. 7 STEERING WHEEL. 8 8 8 Removal... Inspection. Installation. 9 ‘STEERING COLUMN ASSEMBLY 10 Construction 10 Removal. : Disassembly 1" Inspection " Assembly 12 Installation. 12 STEERING GEAR BOX......... 13 Construction 13 Removal 13 Disassembly... 14 Inspection wenn soon 7 ‘Assembly, 19 Installation 24 POWER CYLINDER oe 25 Construction oe 25 Removal, sen 26 Disassembly...... aT Inspection ne 29 Assembly 30 Installation ern 32 STEERING LINKAGE oss 35 Construction 35 Removal and Disassembly ..eccenrnnnns 36 Inspection 36 ‘Assembly and Installation 37ERVI E DATA AND SPECIFI General Specifications ema ion reer : ergo = steering: Bwana =a ‘Steering mm (in), ue Sc" leeraewuse = asia were fon a em so men = ram on)| 1862) | 151 685 cere oe ial ‘directly coupled to oars 7 ao aoe coo r mom “oom [asivomiwee |e] cat (coe omelet [Ee ‘STEERING WHEEL ATI Inspection and Adjustment AVAILABLE SHIMS steeng what lay a oe sie Triimean | Mit fai to ‘Severe whet ewton swing rae L554) ov ne Tava rag] #29. coos oem, asa Sicaringgeurtox | 0808-0081, seo si | tcp — 1.605 - 1.625 (oom dow, tase (oom 008 PHS POWER CYLINDER Modei_| we Dimeanion 1 | Dinenion 2 | Dimeon 13 Chor [000A | Tatas | Secon | aston ccsomany | 3i00 osi0m | axenin | Os4ssn5i Cro2 | 1000 | Sada 127 12 | Seen | 905928 ee ccunon | si00_| “Sinn | Gorsiom | @202%%m | 36.0365 ‘ara | S000] — Lang [11130 | oe THD 05S (Guanen) | soo ‘arsiom | queen | (osoaadim som Fa] on] Aron} sie | oro eseona | 3500 gsiserm | Gem | as7masssoin ar | tom — Sided 12s 5-129Sn | — een] 110-11. creuratcy| Sooo | “Sto | 'Gsesion | Gam | atoossaaiem | S000] Lane "nen 12503-1283 recut) | 00 Gidem | dseiesrem REVISED 04/02 ST-2SERVICE DATA AND SPECIFICATIONS Tightening Torque Unit a ee ‘Socring whee! Inetalation Steering whee! nut 28-32__-27-39 20-24 ‘Sering column shat assembly Upper joint pinch bolt 16-24 16-21 12-15 “Sleering column SU" 4g 99 4e-22 12-18 ng bot Titlock lever SeCUNMG oy a7 24-27 15-20 bolt “leering column shat assembly instalation Clamp sewing tot 27-56 28-97 a0-27 Sa o” Bal maassemoir be 15.95 gis-oas 14-18 Rear cove secuind yay a7 a8 wm Serer See 7-28 te a0 Front cover securing bot “Sector shaft adjusting 34-53 85-54 25-29 20-29 20-30 4-22 ‘Paman arm securing = 77-26 10-22 190-199 ‘Steering gear box instala- tion Steering gear box securing nut anc pot 68°78 70-81 1-58 Power steering oylinger eno Case overseeing 5 Ht 55-05 #8 Te oa Tae ea Gal ook n= 6 10-2 10-19, Gomrecoras8en0Y rate 10-22 10-189 Power steering motor securing bot Power steering cylinder assembly installation Universal joint secur Ing nut and vot 19-20 19-31 4-22 255 44-s6 a2 eat Balj secuing pt BOTT TOS “ern kaye alr tn rag fot bal int ral wei ws me Brag ed Ba OEE og gp 71g en 118 Toga og ay 1015 108 Beli crank pin lock 1-118 099-12 67-87 plate securing bot S118 099-12 67-8 S$T-3CAUTION: TROUBLE DIAGNOSES AND CORRECTIONS The following tables list only typical examples. To perform an accurate diagnosis, carefully listen to the user's complaints and check the actual vehicle to fully understand under what conditions the symptoms occur. The steering system is directly related to the rear axle, be sure to diagnose the steering system by referring to RA section. ‘® For the trouble diagnoses of steering control system, refer to CS section. Condition Probable cause Corrective action Shaking, shocking or Unstable steering whee! Improper tire pressure ‘© Excessive play in drag rod or ball int ‘¢ Improperly adjusted or worn whee! bearing f¢ Worn king pin thrust bearing Je Improper backlash adjustment of sector shatt in steering gear box Je Deformed or unevenly worn tires or road wheels 1¢ improperly adjusted wheel alignment fo Adjust. ¢ Adjust rod length or replace ball joint. |e Check and adjust preload or replace whee! Jo Adjust Je Correct or replace. Je Adjust toe-in. Heavy steering whee! ‘operation 'e Improper tire pressure Je Improperly lubricated king pin Je Improperly lubricated steering linkage ball joint Je Deformed or interfered steering lintage J+ Improperly adjusted or worn wheel bearing Je Improper backlash adjustment of sector shaft in steering gear box Je Worn or damaged bearing in steering gear box J¢ improperly adjusted wheel alignment Je Lack of steering power assist due to voltage drop fe Adjust Je Apply grease or replace. Je Replace (Ungreased type) Je Correct or replace. Je Check and adjust preload or replace whee! bearing Je Adjust J Replace. J Adjust toe-in J Reler to CS section Vehicle ewerves to right or lett [¢ Loose whee! nuts /¢ Unequal right and left tire pressure ‘© Different type tire or wheel on right and teft ‘¢ Improper alignment (toe-in) ‘Differently worn right and lett tires 1 Improperly adjusted spindle stopper ‘Improperly adjusted brakes Je Maltunctioning steering sensor Worn sensor roller or slide ST-4 Tighten, Adjust. }¢ Replace. ‘© Check and adjust. '¢ Cheok and replace. Adjust. Adjust ‘¢Reler to CS section,TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action ‘Unstable driving in straight-ahead direction [e improper alignment (toe-in) [+ Improperly adjusted or worn wheel bearing J# Loose whee! nuts Je Excessive play in drag rod or ts ‘¢ Improper backlash adjustment of sector shaft in steering gear box | Deformed or unevenly worn tres or road wheels joint 'e Check and adjust Je Check preload and adjust or replace whee! bearing, |e Tighten Je Agjust rod length or replace ball joint. Je Adjust. }* Correct or replace. Excessive steering wheel play ‘@ Improper backlash adjustment of sector gear in steering gear box Je Improperly installed ring gear box fe Adjust je Check condition of installation and tighten, Poor returnability of steering whee! [* Improper meshing of steering wheel gears. '¢ Improper operation of worm shaft and ball nut '¢ Improper alignment (toe-in) Je Improper tire pressure Je Improper backlash adjustment of sector shat in steering gear box Je Disassemble and adjust. Replace faulty parts }¢ Disassemble and clean. Replace faulty parts. Check and adjust Adjust Je Adjust. ST-5PRECAUTIONS AND PREPARATION Precautions CAUTION: Be extremely careful when hoisting and moving heavy objects. These can be extremely dangerous operations. © Always clean working area to prevent foreign matter from getting into parts being assembled or serviced. Use a paper rag rather than a cloth when wiping clean parts. Use of a cloth rag may leave lint or other foreign matter on parts being wiped. ‘© When disassembling or servicing units or parts of a vehicl park it on solid and level ground and chock the wheels. Failure to do so may cause the vehicle to move unexpect- edly. Also, be sure to disconnect battery plug in advance. ‘© When disassembling or servicing the steering gear box and power steering cylinder assembly, always perform with clean hands. It is important to prevent the parts from becoming contaminated by dirt or other foreign matter. When removing or installing any unit, make sure that the vehicle is placed in the straight-ahead driving position. © After tightening castle nut, be sure to install and clinch a inspection and maintenance pro- cedures for the mechanism of the steering system. © For troubleshooting and maintenance of electrically con- trolled power steering system, refer to CS section, ‘© For inspection and maintenance of the steering sensor and forward-reverse switch, refer to CS section. Refer to MM section for servicing power steering motor as a single unit. © Refer to EL section for meter panel and turn signal lamp lever switch. Refer to RA section for servicing rear axle assembly. When disassembling or servicing designated parts, be sure to use special service tools. Special Service Tools Too! number Aalates Description ‘s127 180000 Removing steering wheel Steering wheel puller srro002 ‘sT29020007| Removing ball joint of steering linkage Ball joint remover ? 172500000 Removing ball joint of steering linkage Ball joint remover, ST-6STEERING SYSTEM ST-7 TontralierSTEERING WHEEL ‘sT27 180000 1 2. sooo Removal Remove horn button. Remove steering wheel nut and washer. Using special ser- vice tool (ST27180000), remove steering wheel. COMPONENT PARTS Knob ‘shaft Knob bushing om brush contacting area, Steering whee! put ir [Das - 22 Wm 27-33 kam, 29-24 1) a Horn button Spring ? Horn contact harness. contact plate ff Horn hares Steering whee! Serration Steering column vos Inspection Check steering wheel for deformities, cracks or damage. If necessary, replace with a new one. Check serrations on steering wheel and steering shaft sides. If necessary, replace steering wheel or steering shaft. ST-8FP Front ot veice STEERING WHEEL Installation To install, reverse the order of removal. Observe the following: Steering wheel nut: (O): 26 - 32 N-m (2.7 - 3.3 kg-m, 20 - 24 ft-Ib) CAUTION: ‘© Apply a coat of multi-purpose grease to sliding section of horn contact. © Install steering whee! and horn button as shown at left with vehicle placed in straight-ahead driving position. ST-9STEERING COLUMN ASSEMBLY Construction “steering whee! ‘steering cotuma “steering column bracket ‘it lock lover ‘steering shat Boot Stooring gear tox srro00y Removal 1. Remove steering wheel. Refer to “STEERING WHEEL”. 2. Remove the following parts from steering column assembly. Refer to EL and CS sections. © Meter panel ‘© Turn signal lamp switch Forward-reverse lever and FR switch ‘© Harnesses of above-mentioned units and horn switch 8, Remove instrument panel inner cover and pull out steering cover upward. 4, Remove floor mat and floor panel. Refer to BF section. 5. Remove bolts securing steering column clamp to instrument frame. Then remove steering assembly. CAUTION: When separating steering shaft from steering gear box, be careful not to damage boot. i) It is good practice to remove the boot from steering gear box side before separating steering shaft. ST-10STEERING COLUMN ASSEMBLY Disassembly Bushing Steering column shat. Steering column Column bearing / Storing shat Pioeh bot Pie a4 (ns - 23, 12-19) soap a Washer Horm hares [O}16- 22 (1.6 - 22, 12-18) Snap ring Washer Steering column clamp > ‘steering column bracket ‘Adjusting nut (efthand threads) | Ti took lover EES: honly grease (Sa- 26 21-27,15-29 (Nm hom, ab) (leftnand threads) stron Remove tilt lock lever from steering column clamp. Loosen pinch bolt of steering shaft upper joint and remove steering shatt. Remove steering column from steering column bracket. Remove snap ring on lower side of steering. column. Then draw out column bearing and steering column shaft from column. CAUTION: When drawing out steering column shatt from steering column, be careful not to damage bushing on column upper end with shaft end serration. 5. Remove steering column clamp from stéering column bracket. ae Inspection Clean disassembled parts and carefully check for cracks or damage. It necessary, repair or replace with new ones. STEERING SHAFT © Chock shaft for bending or twisting. If necessary, replace. @ Check universal joint for unsmooth operation or backlash. If necessary, replace. sT-11STEERING COLUMN ASSEMBLY ack position Lock release position be = sre inspection (Cont'd) fe Chock serrations for deformities or damage. If necessary, replace. COLUMN BEARING Check bearing for wear, damage or backlash. If necessary, apply grease or replace. STEERING COLUMN, STEERING COLUMN BRACKET AND STEERING COLUMN CLAMP Check for deformities or damage. If necessary, replace. BOOT Check for cracks or damage. If necessary, replace. Assembly To assemble, reverse the order of disassembly. Observe the following: Steering shaft upper joint pinch bolt: [O16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb) Steering column bracket securing bolt: (Oy): 18-21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb) Tilt tock lever securing bo! (0:21 27 Nem (2.1 - 2.8 kg-m, 15 - 20 ft-lb) CAUTION: Install steering column so that horn harness is positioned on the left side. © When inslalling steering shaft to steering column, apply grease to serration on steering shaft side. ‘© Install tilt lock lever so that the lever is placed in the lock Position with its serration seated in place. Then tighten ‘Securing bolts to the specification. After installation, rel ver to make sure that bracket smoothly slides in entire tilting range without interfering adjacent parts. Installation To Install, reverse the order of removal. Observe the following: Steering column clamp securing bolt: (0): 27 - 36 Nem (2.8 - 3.7 kg-m, 20 - 27 ft-lb) CAUTION: ‘When inserting shaft on ing gear box side into steering shaft, be sure to apply grease to serration. Also, be careful not to damage boot. ST-12STEERING GEAR BOX Construction Sectional view AA Removal Before removal, remove dirt or dust around steering gear box. 1. Remove steering wheel and steering column assembly. Refer to “STEERING WHEEL” and “STEERING COLUMN ASSEMBLY”. 2. Disconnect steering sensor (potentiometer) harness. 3. Disconnect pitman arm from drag rod © Remove cotter pin on the end of ball joint and remove cas- tle nut. © Using special service tool (HT72500000), draw out ball joint from pitman arm. 4, Remove steering gear box securing nuts and bolts, then remove steering gear box. ST-13STEERING GEAR BOX 12-20) GG Harness clamp ‘Shim [O)os- 53 25-54, 25-26) Dh: thom, ty 1): Aways replace ater every isassembiy * : Select proper thickness sit mark srroor9 Sa Disassembly oe = a re ”sig0 cover it seat aN weno al nut assembly ( [yi 27 (17-28, 12-20) {> — Kanes came Qa. BS Needle bering 0 ra, erie pug ng Bearing race arged, Si steering gear box greens stra n NO oe i TNT sen Bearing race onan Go S\ easing ae (uae) — oS Front cone ns ovina, Ones Ponto eer = Pitman erm ‘Spring. i Swing arm Yo ‘Steering sensor housing ‘arm pin ‘Sensor cover é CAUTION: © Before disassembly, surface of gear box. Do not use any cleaning oil or solvent for cleaning, other- wise trouble may be caused to steering sensor. remove dirt or dust from the outer 1. Place pitman arm in a vise, then loosen and remove pitman arm securing nut. Place steering gear box in a vise. Locate sector shatt in the straight-ahead position with slit mark on its end facing down by turning pitman arm. Then lock pitman arm with a block to prevent from turning. ST-14STEERING GEAR BOX stron Disassembly (Cont'd) 3. Using special service tool (ST29020001), remove pitman arm from sector shaft. CAUTION: When removing pitman arm, do not strike with a hammer, nor remove from around limit position of operating range. Failure to do so may cause damage to interior parts of steering gear box. 4. Remove steering sensor (potentiometer) as necessary. CAUTION: ‘© Remove steering sensor (potentiometer) only when neces- sary. ‘© I removing steering sensor (potentiometer) is necessary, put alignment marks on sensor housing and potentiometer in advance to ensure the neutral position for proper Insti lation. After installation, check steering sensor output with interactive diagnosis. Refer to CS section. 5. Remove front cover securing bolts and remove front cover. 6. Install set plate to front cover installation position. ST-15STEERING GEAR BOX ‘et plate OR ae, To 105 (0419) die. c Unit mm (io) srro0r7| 7. Using punch, flatten lock nut clinching. 8. Hold spline side of worm shaft locked and remove lock nut. CAUTION: © Before removing lock nut, make sure that sector shaft is placed in the straight-ahead position with the slit mark fac- ing down, © When removing lock nut, loosen It while holding worm shaft locked. if worm shaft turns when loosening lock nut, ball nut may come apart from worm shaft and be damaged. 9. Remove the following parts: © Bearing race (Small: 31 mm (1.22 in) in diameter, 1 mm (0.04 in) thick] © Thrust needle bearing © Bearing race (Large: in) thick} 10 mm (1.57 in) in diameter, 4 mm (0.16 10. Remove set plate and remove steering sensor housing. CAUTION: Be careful not to drop springs In housing. ‘ST-16STEERING GEAR BOX Disassembly (Cont'd) 41. Remove the following parts. © Bearing race [Large: 40 mm (1.57 in) in diameter, 4 mm (0.16 in) thick] © Thrust needle bearing © Bearing race (Small: 31 mm (1.22 in) in diameter, 4 mm (0.16 in) thick] cauTior Also be sure to remove O-ring on the mating surface face of ‘sensor housing. 12, Remove side cover securing bolts. CAUTION: Make sure that sector shaft is placed in the stré position with the slit mark facing down. NOT! Sector shaft can be removed together with side cover. 18. Draw out sector shaft together with side cover from steer- ing gear box and remove packing, CAUTION: © When side cover is sticking and cannot be removed, pry the cover with screwdriver to release. © When drawing out sector shaft, be careful not to damage the shaft threads, serrations, gear tooth and oil seal. 14, Remove adjusting bolt lock nut and loosen adjusting bolt. Then remove sector shatt from side cover. 15. Remove dust cover on the serration side of worm shaft Then remove rear cover securing bolts and remove rear cover. 16. Draw out worm shaft together with ball nut assembly. CAUTION: ‘© Do not disassemble ball nut assembly. © Do not stand removed worm shaft straight up. Always per form servicing with the shaft placed horizontally. Failure to do so may cause ball nut to come apart and drop under its ‘own weight and be damaged. Inspection Clean disassembled parts and check for cracks or damage. if necessary, correct or replace with new ones. BALL NUT ASSEMBLY © Rotate worm shatt to check ball nut for smooth operation. If dragging or backlash is observed, replace as an assembly. © Check for rotation starting torque when assembling balll nut It it exceeds the specification, replace as an assembly. ST-17STEERING GEAR BOX chamfered side shim te _srroay Inspection (Cont’d) Rotation starting torque: 0.5 Nem (0.05 kg-m, 0.4 ft-Ib) © Check worm shaft ball groove for dents or cracks. if necessary, replace as an assembly. © Check ball tube and tube clamps for: looseness. If necessary, tighten clamp screws to specified torque. 2 1.5 + 2.5 Nem (0.15 - 0.25 kg-m, 1.1 - 1.8 ft-Ib) © Measure ball nut backlash in axial direction. If it exceeds the specification, replace as an assembly. Ball nut backiash in axial direction: 0.1 mm (0.004 in) © Check worm shaft end serration for deformities or damage. If necessary, replace as an assembly. SECTOR SHAFT © Check for cracks, damage or wear. If necessary, replace with a new one. © Check serration engaged with Pitman arm for deformities or wear. If necessary, replace with a new one. © Measure clearance between adjusting bolt head and sector shatt T groove. If it exceeds the specification, replace shim with new one of proper thickness. Clearance between adjusting bolt head and T groove: 0.1 mm (0,004 in) or less Adjusting bolt shim: Number of ‘Thickness mm (in) shims to select 1.516 - 1.595 mm (0.0596 - 0.0604 in) ‘Available 1.545 - 1.565 mm (0.0608 - 0.0616 in) adjusting bolt | 1.575 - 1.595 mm (0.0620 - 0.0628 in) One shims 11.605 - 1.625 mm (0.0632 - 0.0640 in) 1.635 - 1.655 mm (0.0644 - 0.0852 in) CAUTION: Install shim with larger chamfered threads. REAR COVER AND SIDE COVER BEARINGS © Check rollers and cages for deformities or damage. If necessary, replace as a cover assembly THRUST NEEDLE BEARING IN STEERING SENSOR HOUSING © Check race surface for dents or cracks. If necessary, replace bearing with a new one. © Check rollers and cages for deformities or damages. If necessary, replace bearing with a new one. OTHER PARTS © Check for cracks or damage. If necessary, replace with new ones. CAUTION: For steering sensor (potentiometer) inspection, refer to CS sec- tion. ST-18STEERING GEAR BOX Assombly CAUTION: Assemble while adjusting each part or unit. © Before assembly, apply a coat of multi-purpose grease (NLGI No. 00 or equivalent) to each bearing and oil se: 1. Place steering gear box in a vise, and insert worm shaft together with ball nut assembly. CAUTION: Insert worm shaft with ball nut gear teeth facing sector shaft. 2. Check oil seal lip on sensor housing side to make sure it is not crimped. 3. Install rear cover and tighten bolts to specified torque. (17 - 27 Nem (1.7 - 2.8 kg-m, 12 - 20 ft-b) ciamp titi positon | CAUTION © When installing rear cover, set harness clamp on the cover and tighten them with rear cover securing bolts. (For setting position and angle, see the figure at left.) © Be sure to insert rear cover O-ring. 4. Apply a coat of grease to sector shaft adjusting bolt head, shim and sector shaft T groove. CAUTION: Refer to “Inspection” for shim adjustment. 5. Apply a coat of grease to bearing seating surface of side cover, then insert sector shaft. Lock nut Side cover 6. Tighten adjusting bolt, install sector shaft to side cover, then install lock nut ‘Adjusting serow ST-19STEERING GEAR BOX Assembly (Cont'd) 7. Before installing sector shaft, rotate worm shaft until ball nut gear positions in the center of hole for installing sector shaft, 8. Insert sector shatt in steering gear box. CAUTION: © Apply a coat of grease to sector shaft bearing seating sur- face of steering gear box. © Properly position ball nut and sector shaft so as not to their gears to mesh with one tooth deviated. ‘© Be sure to fit packing on installation surface of side cover. 8. Install side cover and tighten bolts to specified torque. 1D): 17 - 27 Nem (1.7 - 2.8 kg-m, 12 - 20 fttb) CAUTION: When installing side cover, set harness clamp on the cover and tighten them with side cover securing bolts. (For setting posi- tion and angle, see the figure at left.) 10. Set O-ring in groove on sensor housing installation surface. NOTE: Apply a coat of grease to O-ring to keep it in place. ‘Thrvst needle Bearing 11. Install the following parts in that order. ¢ Bearing race [Small: 31 mm (1.22 in) in diameter, 4 mm (0.16 in) thick] ‘¢ Thrust needle bearing @ Bearing race [Large: 40 mm (1.87 in) in diameter, 4 mm (0.16 in) thick] CAUTION: Apply a coat of multi-purpose grease (NLGI No. 00 or equiva- lent) to races and bearings before assembly. ‘Sensor housing ‘tie ting {— Sat roca 12. Apply a coat of grease to inner circumference of sensor housing slide ring, then install sensor housing, ST-20STEERING GEAR BOX ‘Assembly (Cont'd) 18. install set plate on front cover installation position and tighten bolts to specified torque [): Approx. 44 Nem (4.5 kg-m, 33 f-Ib) 14. Install the following parts in that order. ‘© Bearing race [Large: 40 mm (1.87 in) in diameter, 4mm (0.16 in) thick] ‘© Thrust needle bearing © Bearing race [Small: 31 mm (1.22 in) in diameter, 1 mm (0.04 in) thick] © Lock nut CAUTION ‘© Apply @ coat of multi-purpose grease to races and bearings before assembly. ‘© Hand-tighten lock nut while holding serration side of worm shaft by hand to prevent it from turning. 16. With slit mark on sector shaft facing down, temporarily install pitman arm while ing its slit mark with sector shaft slit mark. 16. Turn worm shaft to left by the lock position. Worm shaft protrudes 1.6 mm (0.063 in) at the position. While holding the shaft, hand-tighten lock nut until the clearance in the axial direction is eliminated. CAUTION: Do not tighten lock nut with wrench. 17. Using punch, clinch lock nut at two points onto worm shatt groove CAUTION: © Firmly clinch lock nut so as not to allow gap to appear between lock nut and worm shaft groove. © Be careful not to allow lock nut to turn when clinching. If it has been turned, start again from step 16. 18. Remove set plate and install front cover. (Dj: 34 - 53 Nem (3.5 - 5.4 kg-m, 25 - 39 fb) CAUTION: Be sure to correctly set O-ring in the O-ring groove of front cover ST-21STEERING GEAR BOX ‘Assembly (Cont'd) 18. Position sector shaft so its slit mark faces down. Using the slit mark as the central angle indication, turn worm shaft from lock to lock to check if the total turning angle is within the specification. Total turning angle: P01 series Approx. 4.8 degrees: P02 series Approx. 4.8 degrees ‘CAUTION: if total turning angle is outside the specification, sector shaft gear and worm shaft ball nut assembly gear may be incorrectly meshed. Disassemble them to check and correct, then reas- semble. 20. Measure backlash of sector shatt. © Check to see that pitman arm is tacked to the neutral posi- tion of sector shat. Push and pull pitman arm with a force of approx. 20 N (2 kg, 4.4 Ib) measure the backlash of sector shatt at the front end of pitman arm [151 mm (6.94 in) from the center of sector shatt]. Backlash limit: 0.35 mm (0.0138 In) © If backiash exceeds the limit, adjust using sector shaft adjusting screw. © When adjustment is completed, tighten lock nut to specified torque. 0 - 29 Nem (2.0 - 3.0 kg-m, 14 - 22 fib) 21. After adjusting backlash, remove filler plug from steering gear box and fill multi-purpose grease (NLGI No. 00 or equivalent) into the gear box up to specified amount. Specified amount of grease: 160 - 200 g (5.64 - 7.05 oz) 22. Move pitman arm back and forth to see ‘smoothly. 23. Remove tacked pitman arm, measure turning torque of worm shaft with torque wrench. Worm shaft turning torque: Less than 0.5 N-m (0.05 kg-m, 0.4 ft-b) 24. If steering sensor (potentiometer) has been removed, apply a coat of grease (Nissan Genuine grease or equivalent) to sliding surfaces of swing arm and arm pin inside sensor housing ‘Specified amount of grease: More than 5 g (0.18 oz) ST-22STEERING GEAR BOX ‘Assembly (Cont'd) 25.When the steering sensor (potentiometer) has been removed, install it with alignment marks on sensor housing and steering sensor (potentiometer) aligned, then install sensor cover. Refer to CS section ["‘Steering Sensor (Poten- tiometer) Adjustment"). 26. Fix steering sensor harness in place with clamps as shown at left stroma] 27. Install pitman arm with slit marks on sector shaft and pitman arm aligned 28. Place pitman arm in a vise and tighten pitman arm secur- ing nut to specified torque. (0): 177 - 216 Nem (18 - 22 kg-m, 130 - 159 ft-lb) 29. Install dust cover on worm shaft rear cover. ST-23STEERING GEAR BOX Installation To install, reverse the order of removal. Observe the following: Steering gear box securing nut and bolt: 1D): 69 - 78 Nem (7.0 - 8.0 kg-m, 51 - 58 ft-lb) Drag rod ball joint castle nut: [O88 - 147 Nem (10 - 15 kg-m, 72 - 108 ft-Ib) CAUTION: Make sure that ball joint tapered portion and threads are free from oil or other lubricant. ‘© Apply a coat of grease to ball joint dust cover lip. ‘ST-24POWER CYLINDER Construction urinog, _ 09 Bun29s s0}0"1 (Guuds woerydeja) ound ya. 2996 o1pt ST-25 a x20 seyooun09 ug 90 1907 soyeora nu 39207 buywog. ma 9001 Aqui a 10a 8uPOWER CYLINDER Removal CAUTION: Grease of very low viscosity Is sealed into power steering cyl- inder assembly. When removing the assembly, be careful not to spill the grease. 1. Remove battery from vehicle. Refer to BC section. NOTE: When performing the work in the pit or the vehicle is being lifted, the power steering cylinder assembly can be removed without removing the battery. 2, Remove floor mat and floor panel. Refer to BF section. 3, Remove pedal bracket assembly. Refer to BR section. 4. Disconnect harness connectors to power steering motor and sensors (option). 5, Remove drag rod from power cylinder. @ Remove cotter pin from the front end of ball joint and remove castle nut. ¢ Using special service tool (HT72500000), remove ball joint from power cylinder assembly. 6. Remove power cylinder from bell crank © Remove cotter pin from the front end of ball joint and remove castle nut. ¢ Using special service tool (HT72500000), remove ball joint from bell crank 7. Remove universal joint securing nuts and bolts on the front ‘end of power cylinder, then remove power cylinder assem- bly from the frame, ‘ST-26POWER CYLINDER Disassembly Baa 0102 1600 i) ST-27sro POWER CYLINDER assembly (Cont'd) 1. Horizontally place power cylinder assembly in a vise with power steering motor positioned aboved the assembly. Then remove the motor from the assembly. CAUTION: ‘© When placing power cylinder assembly, set the assembly so that its gear case flange is gripped by the jaws. © Be careful not to drop the motor. ‘© When the motor Is sticking and cannot be removed, tap it with a plastic hammer to release. ‘© Refer to MM section for overhauling the motor. © Be careful not to lose the coupling of motor shaft and pin- Jon gear. 2. Put alignment marks on universal joint assembly and case cover. Then loosen tube lock nut on the gear case side, and remove the tube together with the universal joint assembly. CAUTION: © Properly put alignment marks so that the configuration of the motor and universal joint assembly installation hole can be correctly determined when reinstalling. © Universal joint assembly need not be removed from the tube unless It shows any damage. 3. Put alignment marks on connector and ball nut assemblies. Then loosen lock nut and remove the connector assembly. ‘@ Using a oair of pliers, remove boot clamp. Then bend boot to gain access to lock nut ‘@ Loosen connector lock nut, then turn connector assembly to remove from ball screw assembly. CAUTION: @ When removing connector assembly, be careful not to e rod of ball screw assembly. ‘on the front end of connector assembly need not be removed unless it shows any damage. 4, If necessary, remove ball joint from connector assembly. © Loosen ball joint lock nut and remove ball joint by rotating it, NOTE: Put alignment marks on ball joint and connector before remov- ing the ball joint for easier reassembly. ST-28POWER CYLINDER Disassembly (Cont'd) 5. Remove gear case cover securing bulls, and remove case cover and gasket from gear case. CAUTION: ‘¢ Be careful not to drop gears, bearings or washers from the gear case. ‘When the cover is sticking to the gear case, tap it with a plastic hammer to remove. 6. Remove gears, bearings and shims, then draw out ball screw assembly. CAUTION: @ Do not stand removed ball screw assembly straight up. Always perform servicing with the assembly placed hori- zontally. Failure to do so may cause ball nut to come apart and drop under its own weight and be damaged. ‘© Do not disassemble ball screw assembly. Inspection Clean disassembled parts and check for cracks or damage. If necessary, replace with new ones. UNIVERSAL JOINT ASSEMBLY Check the following items. If necessary, replace as an assem- bly. © Play in the axial and bending direction © Bearing for backlash © Spider for cracks or damage © Yoke for cracks or damage Also check lubricating condition. if it is insufficient, apply grease through grease nipple on spider. BALL SCREW ASSEMBLY Check the following items. If necessary, replace as an assem- bly © Ball screw threads on rod for dents, damage or deformities © Nut gear for damage, deformities or stepped wear @ Nut for dragging or unstable rotation BEARING Check for backlash or seizure. If necessary, replace with anew one. PINION GEAR AND IDLE GEAR © Check gear teeth for damage or abnormal wear. If necessary, replace with a new one. © Check pinion gear spline for deformities or damage. If necessary, replace pinion gear with a new one. GEAR CASE AND CASE COVER Check for cracks or damage. If necessary, replace with a new one. BOOT Check for cracks or hardening. If necessary, replace with a new one. ST-29“a8 eam (189 Imp Bearing aie Disk spring Washer POWER CYLINDER Inspection (Cont'd) DISC SPRING AND WASHER @ Check for cracks or damage. If necessary, replace with a new one. © Check dise spring for fatigue. If necessary, replace with a new one. PINION GEAR COUPLING Check spline for damage, deformities or wear. If necessary, replace coupling with a new one. CONNECTOR ASSEMBLY ‘© Check ball joint ball stud for twisting or play between stud and socket. If necessary, replace with a new one. © Check dust cover for cracks or damage. If necessary, replace with a new one. GASKET Always replace after every disassembly. Assembly CAUTION: Assemble while adjusting each part or unit. Before assembling, apply multi-purpose grease to each bearing, gear and ball stud in power cylinder assembly up. to the total amount of 200 to 250 g (7.05 to 8.82 oz). @ Always use the same brand of grease for power cylinder component paris. 1. Install ball screw assembly bearing in gear case. CAUTION: Be sure to install bearing with thicker side of outer race facing gear case. 2. Install pinion gear bearing and idle gear bearing in gear case. CAUTION: © Install disc springs and washers in that order before install- ing bearings. © Be sure to position disc springs so that the perimeter areas will contact washers. © After assembly, push bearings toward gear case (direction of arrow) to see if bearings move smoothly. 3. Horizontally place gear case in a vise, then install ball screw assembly onto the case. CAUTION: Apply a coat of grease to worm and ball screw threads of ball screw assembly. 4. Install pinion gear and idle gear in gear case. ST-30srro0e| ate gear bearing inion gear bearing Gear case cover Packing Gear case POWER CYLINDER ‘Assembly (Cont'd) 5. Install plate and bearing of ball screw assembly onto case cover. cauTior Be sure to install bearing with thicker side of outer race facing case cover 6. Install pinion gear bearing and idle gear bearing onto case cover. CAUTION: Be careful not to mix these bearings up as they have the same outer diameter. 7. Install case cover onto gear case with a gasket inserted between them. [D): 54 - 64 Nem (5.5 - 6.5 kg-m, 40 - 47 ft-lb) CAUTION: © Carefully install case cover so that each bearing in the cover and corresponding gear shaft are positioned in place. © Be sure to install coupling onto pinion gear shatt. 8 Connect tube to gear case. © Screw lock nut onto tube and apply liquid packing to tube threads, then screw tube into gear case. CAUTION: When installing tube as a single unit (in case of the universal Joint assembly has been removed from the tube), be sure to connect the longer usable threads side of the tube. ‘© Screw tube until it contacts the plate in gear case. Turn shaft with fingers to check if the pinion gear rotates smoothly and there is no play in the axial direction. If found to be normal, tighten lock nut. Also, check to ensure that universal joint can be installed in its original position using alignment marks put on the joint and the motor before disassembly. (D): 59 - 78 Nem (6 - 8 kg-m, 43 - 58 ft-1b) Pinion gear rotation starting torque (for reference): 2.9 - 7.8 Nem (0.3 - 0.8 kg-m, 2.2 - 5.8 t-lb) ‘ST-31SERVICE DATA AND SPECIFICATIONS Universal joint assembly us nh Tbe 6542 mm (2564000 tn) t) Boot REVISED 11/02 Assembly (Contd) Install universal joint assembly on (if previously removed or replaced with new one) tube Fully screw lock nut onto tube and apply liquid packing to tube threads. ‘© Screw universal joint assembly until dimension “L1" standard, then temporarily tighten lock nut, is the Install ball joint (if previously removed) to connector. Screw lock nut onto ball joint, then screw ball joint onto connector. © Screw until the distance between the center of ball joint and the end of connector reaches the dimension given in the figure, then tighten lock nut to specified torque. 177 - 216 Nem (18 22 kg-m, 130 - 159 ft-Ib) oO CAUTION: Be sure to Install ball joint to connector In correct direction by Confirming alignment marks put before disassembly. 411. Install connector assembly to ball screw assembly. © Turn rod of ball screw assembly counterclockwise until it contacts the back end of tube, and position rod so thal it is at its shortest length. ‘© Install boot and screw nut onto rod. Then screw connector assembly. © Screw connector assembly until dimension “L2" standard, then tighten lock nut to specified torque. is the (0): 177 - 216 Nem (18 - 22 kg-m, 130 - 159 f-1b) 12, Fit boo! lip to gear case and connector grooves beforehand, CAUTION: Do not clamp boot engaging portions at this stage. 13. Install power cylinder motor with gasket and tighten secur- ing bolts to specified torque. (DJ: 19 - 30 Nem (1.9 - 3.1 kg-m, 14 - 22 ft-lb) Installing, check to see if coupling connecting motor shaft and pinion gear shaft Is attached, Installation 1. Install universal joint on frame, and tighten securing bolts and nuts to specified torque. (OJ: 43 - 55 Nem (4.4 - 5.8 kg-m, 32 - 41 ft-lb) CAUTION: Position clips for motor harness clamps and tighten them tog P/S POWER CYLINDER Model | we | Wheel Bae | Dimension LI | Dimension L2 ‘ceo | 3000 1775-129 Sam | 569mm cusniony |_ 3500 (502-510%n) | 20232) ‘Craz_—| 3000 1275-129 5mm | 565mm (uation) | 000 | isan | (S02-5.10im) | @.20-232in) ‘Cara2 | S000] — Long | 1275-139:5mm | $6-59mm (cusniony | 6000 (502-5.10%n) | @220232in) 8000 Par] “3000 | ar Too | 335m Pveumasiey | 3500, 551567in) | 2106in) Por] ~000 | Sandard | 1255-1295mm | — 4mm Preumaey | S000 | Shor) | 4.988:10%m) | 55m) “Gaz | soo} — Long 28mm @veumaicy | 6000 ai3siny ST-32POWER CYLINDER Stallation (Cont'd) 2. Check to see that the motor is 60 positioned that it will not interfere with adjacent parts on body side. Then tighten tube lock nut on the universal joint side (if temporarily tightened) to specified torque. (Dy: 59 - 78 Nem (6 - 8 kg-m, 43 - 58 ft-Ib) Par wenee 3. Draw out connector by turning together with ball screw assembly until ball joint is placed in installation position on bell crank side, NOTE: It is good practice to remove the boot engaging portion on the gear case side beforehand. Be careful not to allow dust or other foreign matter to enter the case. 4, Tighten engaging portions at both ends of boot with clamps. 5. Insert ball joint of connector into installation position on bell crank side, and tighten castle nut to specified torque. (0): 98 - 147 Nem (10 - 15 kg-m, 72 - 108 ft-lb) CAUTION: © Apply a coat of grease to lip of ball joint dust co ‘© Check ball joint threads and tapered area for oil or paint adhesion. If necessary, wipe them clean. 6. Install ball joint of drag rod on power cylinder assembly, and tighten castle nut to specified torque. [Dy 98 - 147 Nem (10 - 15 kg-m, 72 - 108 fib) caUTIO! © Apply a coat of grease to lip of ball joint dust cover. © Check ball joint threads and tapered area for oil or paint adhesion. If necessary, wipe them clean. 7. Connect harness connectors to power cylinder motor and sensor (option). Power steering motor = sTTo049| ST-33POWER CYLINDER Installation (Cont'd) 8. Install pedal bracket assembly. Refer to BR section. 9. Install floor panel and floor mat. Refer to BF section, 10. Install battery on vehicle. Refer to BC section, ‘ST-34STEERING LINKAGE ConstructionSTEERING LINKAGE Removal and Disassembly 1. Jack up rear of vehicle. Refer to Gi section 2. Remove steering tires. Refer to MA section CAUTION: For pneumatic tires, bleed a slight amount of air before removal 3. Remove drag rod assembly by referring to “POWER CYLINDER” and “STEERING GEAR BOX". 4, Remove ball joint of power steering cylinder assembly from bell crank by referring to “POWER CYLINDER” 5. Remove rear axle assembly from vehicle. Refer to RA sec- tion 6. Remove tie-rod ball joints trom left and right spindle arms. Remove by extracting cotter pins and loosening ball joint nuts. © Using special service tool (ST29020001), draw out ball joint from spindle 7. Remove bell crank pin lock plate securing bolts from axle center, then draw out bell crank pin upward. Remove bell crank from axle center. Remove left and right tie-rods from bell crank. @ Remove by extracting cotter pins and loosening ball joint nuts. Using ball joint remover, remove ball joint from bell crank 10. Extract upper and lower grease seals from the pin hole of belt crank 11. Remove needle bearings from pin hole of bell crank. Using drift, drive each bearing out from the inner side. Inspection Clean disassembled parts and check for cracks or damage. If necessary, replace with new ones. ‘ST-36Ball sud STEERING LINKAGE Inspection (Cont'd) TIE-ROD © Check rod for deformities or damage. If necessary, replace with a new one. © Check ball joint ball stud for twisting or play between stud ‘and socket. If necessary, replace balll joint with a new one. © Check dust cover for cracks or damage. If necessary, replace with a new one. DRAG ROD ASSEMBLY © Check rod for deformities or damage. If necessary, replace with a new one. © Check ball joint ball stud for twisting or play between stud and socket. If necessary, replace ball joint with a new one, © Check dust cover for cracks or damage. If necessary, replace with a new one. NEEDLE BEARING Check for damage or abnormal wear. If necessary, replace bearing and grease seal as a set. GREASE SEAL Always replace after every disassembly. Assembly and Installation 1. Press-fit needle bearings into upper and lower sides of bell crank pin hole. 2. Insert grease seals into upper and lower sides of bell crank pin hole. 3. Connect left and right tie-rods to bell crank. © Insert ball joint into connection holes on bell crank, then tighten castle nuts to specified torque. (Dy: 98 - 147 Nem (10 - 15 kg-m, 72 - 108 ft-b) CAUTION: © Apply a coat of grease to lip of ball joint dust cover. © Check ball joint threads and tapered area for oil or paint adhesion. if necessary, wipe them clean. 4, Install bell crank in axle center. © Face bell crank pin-to-lock engaging groove (on bell crank pin) to lock plate installation position, then insert bell crank pin. @ Engage lock plate with bell crank pin groove, then tighten securing bolts to specified torque. [Py 9.1 - 11.8 Nem (0.93 - 1.2 kg-m, 6.7 - 8.7 ft-4b) ST-37SERVICE DATA AND SPECIFICATIONS ‘Assembly and Installation (Cont'd) CAUTION: © Fill grease into bell crank through grease nipple on the shaft. © If lock plate shows slepped dents caused by bell crank pin being hit, replace with a new one. 5. Connect tie-rods to lett and right spindle arms. Insert ball joint in spindie arm, and tighten castle nuts to specified torque. [D): 98 - 147 Nem (10 - 15 kg-m, 72 - 108 fib) CAUTION: ‘© Apply a coat of grease to lip of ball joint dust cover. Check ball joint thread and tapered area for oil or paint adhesion. If necessary, wipe them clean. 6. Install rear axle assembly on vehicle. Refer to RA section. 7._ Install balt joint of power cylinder assembly on bell crank by referring to “ POWER CYLINDER” 8. Instali drag rod by referring to “POWER CYLINDER” and "STEERING GEAR BOX”. '® Loosen lock nuts, Adjust L3 the center-to-center distance of 4 ball joints on the ends cf drag rod to the standard by rotating the ball joints. IS POWER CYLINDER Model | We | Whee! Base | Dimension L3 ‘ero —| 3100 a 358.6857 bom eusmon) | 3500 (3345-3375 in) srro%s| “cro: —|—si00 | —Sandand 995-998 am (euston) | S000 | Shor) | 643-3655) ‘Capea ~|—s000 | — Long [70235-1006 eam (Gusmion) | 6000 (4030-4041 in) 100, Por] 3100 al DOT EDIOG (Preamavic) | 3500 (35732-35850 in) PO | ai) —Sandaed 11201-1123 tem Poeamaic) | si00_| Shor) | (44098-44216 5) GPez | ~Si00 | — Long | 1260.3-1263 3mm (@oeumatc) | 6100 (49618-49-736i9) 9. Install steering tires, and tighten wheel nuts. Refer to RA section, CAUTION: For pneumatic tires, inflate tir to specified alr pressure. 10. Remove jack and wooden block from the rear of vehicle and lower vehicle body. 11. Adjust toe-in by referting to RA section. REVISED 11/02 ST-38