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Steering Gearbox Installation

  1. Install the pinion shaft grommet (A) on the valve housing.
    NOTE: If the return line fitting (B) is removed, install it.
    Fig 1: Installing Pinion Shaft Grommet And Return Line Fitting
    G03641151Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Slide the steering gearbox (C) between the front suspension subframe and body from the driver's side. Place the gearbox in position on the front suspension subframe.
  3. Install the gearbox stiffener bracket (A) on the front suspension subframe, and tighten the bolt and nut to the specified torque.
    Fig 2: Installing Gearbox Stiffener Bracket
    G03641152Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Loosely install the two 10 mm flange bolts on the left side of the gearbox.
    Fig 3: Installing Two 10 mm Flange Bolts On Left Side Of Gearbox
    G03641153Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the mounting cushion (A) on the right side of the gearbox.
    Fig 4: Installing Mounting Cushion On Right Side Of Gearbox
    G03641154Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the mounting bracket (B) over the mounting cushion, then install the two 10 mm flange bolts (C). Tighten the four 10 mm flange bolts for the gearbox to the specified torque.
  7. Connect the return hose (A) securely, and tighten the adjustable hose clamp (B) (see POWER STEERING HOSE, LINE, AND PRESSURE SWITCH REPLACEMENT  ).
    Fig 5: Connecting Return Hose
    G03641155Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Connect the feed line (C), and tighten the 16 mm flare nut (D) to the specified torque.
  9. Install the P/S line mounting brackets (A) on the front suspension subframe and gearbox mounting bracket.
    Fig 6: Installing P/S Line Mounting Brackets
    G03641156Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Carefully raise the front suspension subframe with the transmission jack (transfer case supporting jack).
  11. Install the front suspension subframe rear brackets (A). Tighten the 12 mm flange bolts (B) and 14 mm special bolts (C) to the specified torque.
    Fig 7: Installing Front Suspension Subframe Rear Brackets
    G03641157Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install the front suspension subframe front brackets (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to the specified torque.
    Fig 8: Installing Front Suspension Subframe Front Brackets
    G03641158Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Lower the front suspension subframe supporting jack and the transmission jack.
  14. Install the splash shield (A).
    Fig 9: Installing Splash Shield
    G03641159Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install the propeller shaft protector.
    Fig 10: Installing Propeller Shaft Protector
    G03641160Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Connect the power steering pressure (PSP) switch connector (A).
    Fig 11: Connecting Power Steering Pressure (PSP) Switch Connector
    G03641161Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Connect the three way catalytic converter (TWC) (A) to the mufflers (B). Install the new 10 mm self-locking nuts and tighten them to the specified torque.
    Fig 12: Connecting Three Way Catalytic Converter (TWC) To Mufflers
    G03641162Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Install the exhaust rubber mount on the frame.
    Fig 13: Installing Exhaust Rubber Mount On Frame
    G03641163Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Install the front suspension subframe stiffener plate.
    Fig 14: Installing Front Suspension Subframe Stiffener Plate
    G03641164Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Install the 10 mm flange bolts on the engine side mount bracket (A).
    Fig 15: Installing 10 mm Flange Bolts On Engine Side Mount Bracket
    G03641165Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Connect the pump outlet hose (A) from the power steering pump, and install the feed hose clamp (B).
    Fig 16: Connecting Pump Outlet Hose From Power Steering Pump
    G03641166Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.
    Fig 17: Reconnecting Tie Rod Ends To Steering Knuckles
    G03641167Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Install the new cotter pin (C) and bend it as shown.
  24. Center the steering rack within its stroke, then install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:
    • Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft).
    • Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft.
    • Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten the lower joint bolt to the specified torque.
      Fig 18: Installing Steering Joint
      G03641168Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Center the cable reel first by rotating it clockwise until it stops. Then rotate it counterclockwise (about two and half turns) until the arrow mark on the label points straight up.

    Reinstall the steering wheel (see STEERING WHEEL INSTALLATION  ).

  26. Install the steering joint cover (A) with the clamps (B) and clips (C).
    Fig 19: Installing Steering Joint Cover Using Clamps And Clips
    G03641169Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Install the front wheels.
  28. Connect the negative battery cable.
  29. Fill the system with power steering fluid, and bleed air from the system (see FLUID REPLACEMENT  ).
  30. After installation, perform the following:
    • Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks (see FLUID LEAKAGE INSPECTION  ).
    • Adjust the front toe (see WHEEL ALIGNMENT ).
    • Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally, if necessary.
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