### Power Rack and Pinion

#### REMOVAL AND INSTALLATION

##### Sentra and 200SX

1. Raise and support the vehicle safely.
2. Disconnect the low pressure hose clamp and remove the low pressure hose at the steering gear. Be sure to use a pan to catch the fluid.
3. Disconnect the flare nut and the high pressure tube at the steering gear, then drain the fluid from the gear.
4. Remove the tie rod ends from the steering knuckle.
5. Place a floor jack under the transaxle and support it.
6. Remove the front exhaust pipe and remove the rear engine mount.
7. Position the front wheels so they are pointing straight ahead.
8. Matchmark the steering column lower joint to the steering gear.

   NOTE: The steering gear splines have a flat spot or key way. Be sure to note this during removal.

9. Remove the bolt that secures steering column lower joint.
10. Unbolt and remove the steering gear unit and the linkage.

    To install:

11. Install the power steering gear assembly to the vehicle. Align the steering column to the steering gear.

    NOTE: Be sure to align the flat spot or keyway during installation.

12. Install the steering gear mounts and tighten the mounting bolts in sequence to 54–72 ft. lbs. (73–97 Nm).

    Fig. 1: Mounting bolt torque sequence — 1995–97 Sentra and 200SX

13. Install the pinch bolt for the steering column-to-gear connection and tighten the bolt to 17–22 ft. lbs. (24–29 Nm).
14. Connect the tie rod ends to the steering knuckle and tighten the mounting nut to 22–29 ft. lbs. (29–39 Nm).
15. Tighten the tie rod mounting nut further so the groves in the nut align with first cotter pin hole. Install a new cotter pin.
16. Connect the power steering low pressure hose to the steering gear and tighten the fitting to 20–29 ft. lbs. (27–39 Nm).
17. Connect the power steering high pressure hose to the steering gear and tighten the fitting to 11–18 ft. lbs. (15–25 Nm).
18. Install the rear engine mount and remove the floor jack.
19. Using new gaskets, install the front exhaust pipe assembly.
20. Fill the power steering system and start the engine.
21. Bleed the power steering system and check the wheel alignment.

##### Altima and 240SX

Fig. 2: Power steering gear assembly — 240SX

CAUTION
The air bag system must be disarmed before removing the rack and pinion. Failure to do so may cause accidental deployment, property damage or personal injury.

1. Disconnect the negative battery cable and disarm the air bag.
2. Raise and safely support the vehicle as necessary.
3. Remove the bolt securing the lower steering column shaft to the power steering gear assembly. Be sure to matchmark the shaft from the steering gear to the steering column joint for correct installation.
4. Disconnect the hoses from the power steering gear and plug the hoses to prevent leakage.
5. Remove the cotter pins and castle nuts from the tie rod ends.
6. Using a ball joint separating tool, remove tie rod ends from the steering knuckle.
7. Remove the front exhaust pipe mounting nuts and bolts. Remove the front exhaust pipe from the vehicle.
8. If necessary, disconnect the control cable or linkage from the transmission and position it out of the way.
9. Remove the power steering gear mounting bolts or nuts.
10. Remove the steering gear from the vehicle. Use care when separating the steering column joint.
11. Inspect the steering gear mount bushings and replace as necessary.

    To install:

12. Align the steering column-to-steering gear matchmark and install the steering gear to the vehicle. Be sure to properly install the mounting bushings and hand tighten the mounting nuts or bolts.

    NOTE: When installing the lower steering joint to the steering gear, make sure that the wheels are aligned straight and the steering joint slot is aligned.

13. Tighten the steering gear mounts as follows:
    1. 1993–97 240SX — Tighten to 65–80 ft. lbs. (88–108 Nm)
    2. 1993–96 Altima — Tighten to 54–72 ft. lbs. (73–97 Nm)
14. Install the pinch bolt securing the lower steering column shaft to the power steering gear assembly. Tighten the pinch bolt to 17–22 ft. lbs. (24–29 Nm)
15. Install the tie rod end to steering knuckle and tighten the castle nut to 22–29 ft. lbs. (29–39 Nm)
16. Tighten the castle nut further to align the slot in the castle nut with the cotter pin hole and install a new cotter pin.
17. If removed, connect the control cable or linkage to the transmission and position it out of the way.
18. Using new gaskets, install the front exhaust pipe assembly.
19. Connect the power steering hoses to the steering gear and fill the power steering reservoir.
20. Start the engine and refill the power steering reservoir.
21. Bleed the power steering system and perform a front end alignment.
22. Connect the negative battery cable.
23. If equipped, enable the air bag system.

##### Maxima

Fig. 3: Rack and pinion bolt tightening sequence — Maxima

1. Disconnect both battery cables and wait at least 10 minutes after the battery cables are disconnected. This will disarm the air bag system so the steering wheel can be removed.
2. Point the front tires straight ahead and lock the steering in this position.

   WARNING
   Do not turn the steering wheel or column with the lower joint removed from the steering column or the spiral cable may be damaged.

3. Remove the steering wheel.

   CAUTION
   The air bag system must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment, property damage or personal injury.

   NOTE: The steering wheel must be removed before disconnecting the steering column lower joint to avoid damaging the SRS spiral cable.

4. Raise and support the vehicle safely and remove the front wheels.
5. Disconnect the tie rod ends from the steering knuckles.
6. Remove the carbon canister from the vehicle.
7. Support the engine then remove the bolts attaching the engine mounts to the engine mounting center member. Remove the engine mounting center member.
8. Remove the front stabilizer bar from the vehicle.
9. Remove the nuts attaching the hole cover to the bulkhead.
10. Move the hole cover aside and disconnect the lower joint from the rack and pinion. Matchmark the pinion shaft and the pinion housing to record the steering neutral position.
11. Disconnect the power steering fluid pipes from the rack and pinion.
12. Remove the bolts attaching the mounting brackets and remove the rack and pinion from the vehicle.

    To install:

13. Position the rack and pinion in the vehicle and install the mounting brackets. Torque the mounting nuts and bolts in the proper sequence to 54–72 ft. lbs. (73–97 Nm).
14. Install new O-rings to the power steering fluid pipes and connect them to the rack and pinion. Torque the low pressure line 20–29 ft. lbs. (27–39 Nm). Torque the high pressure line to 11–18 ft. lbs. (15–25 Nm).
15. Align the lower steering joint to the pinion shaft and install the joint onto the pinion shaft. Install the bolt and torque the bolt to 17–22 ft. lbs. (24–29 Nm).
16. Properly position the hole cover and install the attaching nuts, torque the nuts to 2.9–3.6 ft. lbs. (4–5 Nm).
17. Install the front stabilizer.
18. Install the engine mounting center member and torque the attaching bolts to 57–72 ft. lbs. (77–98 Nm). Attach the engine mounts to the center member and torque the bolts to 57–72 ft. lbs. (77–98 Nm). Remove the support from the engine.
19. Install the remaining components in the reverse order of removal.
20. Tighten the tie rod end nuts to 46–61 ft. lbs. (63–82 Nm), then install a new cotter pin.
21. Fill the power steering reservoir with fluid and bleed the air from the power steering system.
22. Check the vehicle front end alignment and adjust as necessary.

##### 300ZX

WARNING
On air bag equipped vehicles, the rotation of the spiral cable is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed.

1. Raise and support the vehicle safely.
2. Disconnect the electrical connector from the solenoid valve.
3. Position an oil catch pan under the power steering gear, remove the hydraulic lines from the gear and drain the oil. Plug the lines to prevent leakage and discard the copper washers.
4. Loosen the steering column lower joint shaft bolt.
5. Before disconnecting the lower ball joint set the steering gear assembly in neutral by making the wheels straight. Loosen the bolt and disconnect the lower joint. Matchmark the pinion shaft to the pinion housing to record the neutral gear position.
6. Remove the tie rod end-to-knuckle arm cotter pins and castle nuts.
7. Separate the tie rods from the knuckle using a suitable puller.
8. Remove the steering gear housing mounting bolts.
9. Position a jack under the engine and raise it just enough to support the engine. Loosen the engine mounting bolts and raise the engine about 1⁄2 in. (12mm).

   NOTE: To prevent damage to engine components, place a block of wood between the engine and the jack, when raising the engine.

10. Remove the steering gear and linkage from the vehicle.

    To install:

11. Install the power steering gear and linkage into the vehicle.
12. Install the lower steering column joint to the steering gear pinion and torque bolt to 17–22 ft. lbs. (22–29 Nm).

    NOTE: Be sure to align the matchmarks during installation.

13. Install steering gear clamps with rack mounting bushings and torque mounting bolts to 65–80 ft. lbs. (88–108 Nm).
14. Connect the tie rod ends to the steering knuckles and tighten nuts to 22–29 ft. lbs. (29–39 Nm). Install new cotter pins.
15. Using new copper washers, connect the power steering lines and torque the high pressure hydraulic line fitting to 22–26 ft. lbs. (36–40 Nm) and lower pressure fitting to 27–30 ft. lbs. (36–40 Nm).

    NOTE: The copper washers in the lower pressure hydraulic line fitting are larger than the washers in the high pressure line. Make sure the washers are installed in the proper fittings. Observe the torque specification given for the hydraulic line fittings. Over-tightening will cause damage to the fitting threads and washers.

16. Connect the electrical connector to the solenoid valve.
17. Lower the engine and tighten the mounting bolts.
18. Refill the power steering pump, start the engine and bleed the system.
19. Perform front end alignment.