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Steering Gearbox Overhaul: Reassembly

  1. Coat the special tool with power steering fluid, then slide it onto the rack, big end first.
  2. Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool.

    Note these items during reassembly:

    • Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the special sizing tool.
    • Replace the piston's O-ring and seal ring as a set.
    Fig 1: Positioning O-Ring
    G01505795Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.
  4. Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
    Fig 2: Coating Piston Seal Ring
    G01505796Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Move the special tool back and forth several times to make sure the piston seal ring fits snugly in the piston.
  6. Wrap vinyl tape around the rack teeth and rack end edges, then coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so that there is no stepped portion.
    Fig 3: Wrapping Vinyl Tape Around Rack Teeth
    G01505797Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Coat the inside surface of the new cylinder end seal (A) with power steering fluid, then install it onto the steering rack with its grooved side toward the piston When installing the cylinder end seal, be careful not damage the lip of the seal with the edges or teeth of the steering rack
    Fig 4: Coating Inside Surface Of New Cylinder End Seal
    G01505798Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  9. Grease the steering rack teeth, then insert the steering rack into the gearbox housing Be careful not to damage the inner surface of the cylinder wall with the rack edges.
    Fig 5: Greasing Steering Rack Teeth
    G01505799Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Insert a deep socket wrench (A) onto the steering rack as shown.
    Fig 6: Inserting Deep Socket Wrench
    G01505800Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press Do not push on the tool with excessive force as it may damage the cylinder end seal.
  12. Remove the tool, and center the steering rack.
  13. Wrap vinyl tape around the rack end edges, and coat the surface of the tape with power steering fluid Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.
    Fig 7: Wrapping Vinyl Tape Around Rack End Edges
    G01505801Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Coat the inside surface of the new cylinder end seal (A) with power steering fluid, then press it into the rack bushing (B) using the special tools.
    NOTE: The open end of the seal should be facing down.
    Fig 8: Coating Inside Surface Of New Cylinder End Seal
    G01505802Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Coat the new O-ring (C) with power steering fluid, and carefully fit it in the groove of the rack bushing.
  16. Install the rack bushing onto the steering rack with cylinder end seal grooved side toward the piston. Push in the rack bushing with your finger.
    Fig 9: Installing Rack Bushing Onto Steering Rack
    G01505803Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  18. Install the rack stop (A) onto the steering rack so the hole (B) is aligned with the slot (C) on the steering rack.
    Fig 10: Installing Rack Stop
    G01505804Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Insert the end of the circlip (A) into the hole (B) of the rack stop (C). Turn the rack stop counterclockwise until the circlip is fully seated in the rack stop.
    Fig 11: Inserting End Of Circlip
    G01505805Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Apply grease to the bearing (A) in the gearbox housing, and install the valve body unit (B) and gasket (C) by engaging the gears. Note the valve body unit installation position (direction of line connections). Then loosely install the two flange bolts.
    Fig 12: Applying Grease To Bearing
    G01505806Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the nut (D) onto the pinion shaft end, and tighten to specified torque.
  22. Install the plug end (F) onto the gearbox housing and tighten it to the specified torque. After tightening, use a drift to stake the plug shoulder (E) against the grearbox housing.
  23. Tighten the flange bolts to the specified torque.
  24. Before installing the cylinder lines, coat the new O-rings with power steering fluid, then install the lines.

    Note these items during reassembly:

    • Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material.
    • Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.

    13 N.m (1.3 kgf.m, 9.4 lbf°Ft) 

    Fig 13: Installing Lines
    G01505807Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Grease the sliding surface of the rack guide (A) with multipurpose grease, and install it onto the gearbox housing.
    Fig 14: Greasing Sliding Surface Of Rack Guide
    G01505808Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Apply new sealant to around the first three threads of the rack guide screw (B), then install the spring (C), rack guide screw and locknut (D).
  27. Adjust the rack guide screw (see Rack Guide Adjustment  ). After adjusting, check that the rack moves smoothly by sliding it right and left.
  28. Install the stop washer (A) and the lock washer (B) on the rack (C). Align the lock washer tabs (D) with the slots (E) in the rack. Install the rack end (F) while holding with lock washer in place. Repeat this step for the other side of the rack.
    Fig 15: Installing Stop Washer
    G01505809Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Hold the flat surface sections of the right side steering rack with a wrench, and tighten the both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.
  30. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
    Fig 16: Bending Lock Washer
    G01505810Courtesy of AMERICAN HONDA MOTOR CO., INC.
  31. Apply multipurpose grease (A) to the circumference of the rack end joint housing.
    Fig 17: Applying Multipurpose Grease
    G01505811Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. Apply a light coat of silicone grease to the boot grooves (B) of the rack ends.
  33. Center the steering rack within its stroke. Install the boots on the rack ends with the tie-rod clips. After installing the boots, wipe the grease off the threaded section (A) of the rack end.
    Fig 18: Wiping Grease Off Threaded Section Of Rack End
    G01505812Courtesy of AMERICAN HONDA MOTOR CO., INC.
  34. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
    Fig 19: Installing New Boot Bands
    G01505813Courtesy of AMERICAN HONDA MOTOR CO., INC.
  35. Close the ear portion (A) of the band with a commercially available pincers, Oetiker 1098 or equivalent (B).
    Fig 20: Closing Ear Portion
    G01505814Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Slide the rack right and left to be certain that the boots are not deformed or twisted.
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