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Steering Gearbox Installation

  1. Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheelwell opening on the driver's side.
    Fig 1: Identifying Cylinder Of Steering Gearbox
    G03652396Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Carefully, move the steering gearbox toward the passenger's side until the pinion shaft clears the wheelwell opening on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position.
    Fig 2: Moving Steering Gearbox Toward Passenger's Side
    G03652397Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the pinion shaft grommet (A).
    Fig 3: Installing Pinion Shaft Grommet
    G03652398Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the gearbox mounting brackets.
  5. Install steering stiffener A, and lightly tighten the gearbox attaching nut and bolts.
    Fig 4: Installing Steering Stiffener And Torque Specifications
    G03652399Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install steering stiffener B with the gearbox attaching nuts and torque them to the specified valve. Then tighten the gearbox attaching nuts and bolts at steering stiffener A to the specified torque values.
    Fig 5: Installing Steering Stiffener With Gearbox And Torque Specifications
    G03652400Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Install the steering rack guard (A).
    Fig 6: Installing Steering Rack Guard
    G03652401Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. On the passenger's side of the gearbox, check for a clearance (A) of 3 mm (0.12 in.) or more between the steering rack guard (B) and boot guard (C). If the steering rack guard is in contact with the boot guard, or if the clearance is less than 3 mm (0.12 in.), adjust the steering rack guard to the correct position.
    Fig 7: Adjusting Steering Rack Guard To Correct Position
    G03652402Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install the body stiffener (A).
    Fig 8: Installing Body Stiffener And Torque Specifications
    G03652403Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Connect the return line (A) securely, and tighten the 16 mm flare nut (B).
    Fig 9: Connecting Return Line And Torque Specifications
    G03652404Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Connect the feed line (C) securely, and tighten the 14 mm flare nut (D).
  12. Install the return hose clamp (A) and feed line clamp (B) on the left side of the gearbox.
    Fig 10: Installing Return Hose Clamp And Feed Line Clamp With Specified Torques
    G03652405Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the return hose clamp (A) and feed line clamp (B) on the right side of the gearbox.
    Fig 11: Installing Return Hose Clamp And Feed Line Clamp With Specified Torques
    G03652406Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Wipe off any grease or contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms. Install the 12 mm nut (B) and tighten it.
    Fig 12: Reconnecting Tie-Rod End To Damper Steering Arms And Torque Specifications
    G03652407Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install a new cotter pin (C), and bend it as shown (D) or (E).
  16. Install the heat shield (A).
    Fig 13: Installing Heat Shield And Torque Specifications
    G03652408Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Install the air cleaner (A).
    Fig 14: Installing Air Cleaner
    G03652409Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. 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.
      Fig 15: Installing Steering Joint And Reconnecting Steering Shaft With Specified Torques
      G03652410Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Install the driver's dashboard lower cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ), and the driver's dashboard under cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ).
  20. Center the cable reel by first 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  ).
  21. Install the front wheels.
  22. Connect the negative cable to the battery.
  23. Fill the system with power steering fluid, and bleed air from the system (see FLUID REPLACEMENT  ).
  24. 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  ).
    • Perform the front toe inspection (see FRONT TOE INSPECTION/ADJUSTMENT ).
    • Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally, if necessary.
    • 2002-2004 models: Do the ECM/PCM idle learn procedure (see ECM/PCM IDLE LEARN PROCEDURE ).
    • Do the power window control unit reset procedure (see RESETTING THE POWER WINDOW CONTROL UNIT ).
    • Enter the anti-theft code for the radio, then enter the customer's radio station presets.
    • Set the clock.
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