See Figures 1 and 2
See Figures 3, 4 and 5
- Remove the steering gear splash shield, if equipped.
- Loosen the rack guide adjusting locknut.
- Tighten the adjusting screw until it compresses the spring and seats against the guide, then loosen it. Torque it to 35 inch lbs., then for 1988-91 models back it off 20-20 1/18 degrees, or for 1992-95 models, back it off to 40-60 degrees.
- Hold it in that position while adjusting the 40mm locknut with a special locknut wrench, part No. 07916-SA50001, or equivalent, to 18 ft. lbs. (25 Nm).
- Recheck the play, and then move the wheels lock-to-lock, to make sure the rack moves freely without undue effort.
Turning the steering wheel from lock-to-lock several times will warm up the fluid. Effort should be no more than 4 lbs. (1.8 kg) for 1988-91 models, or 3.3 lbs. (1.5 kg) for 1992-95 models when measured with a spring scale attached to the steering wheel.
REMOVAL & INSTALLATION
- Disconnect the negative battery cable. Raise the vehicle and support it safely.
- Remove the cover panel and steering joint cover. Unbolt and separate the steering shaft at the coupling.
- Drain the power steering fluid by disconnecting the return hose at the box and running the engine while turning the steering wheel lock-to-lock until fluid stops draining. Remove the gearbox shield, if equipped. Remove the front wheels.
- Remove the cotter pins and unscrew the castle nuts on the tie rod ends. Using a ball joint tool, disconnect the tie rod ends. Lift the tie rod ends out of the steering knuckles.
- If equipped with manual transaxle, disconnect the shift lever torque rod from the clutch housing. Slide the pin retainer out of the way, drive out the spring pin and disconnect the shift rod.
- If equipped with automatic transaxle, remove the shift cable guide from the floor and pull the shift cable down by hand.
- Remove the two nuts connecting the exhaust header pipe to the exhaust pipe and remove the exhaust header pipe (called exhaust pipe A for 1992-95 models). Disconnect the three hydraulic lines from the control unit.
- Slide the tie rod ends all the way to the right and remove the steering rack mounting bolts.
- Drop the gearbox far enough to permit the end of the pinion shaft to come out of the hole in the frame channel, then rotate it forward until the shaft is pointing rearward.
- Slide the gearbox to the right until the left tie rod clears the beam, then drop it down and out of the vehicle to the left.
- Install the gearbox and tighten the bracket bolts to 29 ft. lbs. (40 Nm). If equipped with a manual transaxle, reinstall the pin retainer after driving in the pin and be sure the projection on the pin retainer is in the hole.
- Reconnect the fluid lines and tighten the line from the pump to 28 ft. lbs. (38 Nm), the line to the reservoir to 9 ft. lbs. (13 Nm) and the line to the oil cooler to 20 ft. lbs. (29 Nm).
- Reconnect the tie rod ends and tighten to the proper specification.
- Fill the system with fluid and bleed the air from the system.
Disassembly, Inspection and Assembly
See Figures 6 and 7
- Remove the steering rack assembly from the vehicle and support it in a bench vise.
- Remove the valve body assembly from the gearbox housing, be sure to remove the O-rings and port orifices from the housing.
- Remove the tie rods from the rack by first unbending the lockwashers and then unscrewing the tie rods.
- Push the right end of the rack into the housing to avoid scratching the sliding surface. Loosen the rack screw locknut and remove the rack guide from the housing.
- Remove the 28mm snapring (1988-91) or 35mm snapring (1992-95) from the bottom of the housing, then remove the pinion from the housing by tapping it lightly with a plastic mallet.
The pinion bearing assembly cannot be removed if it shows signs of wear. If the bearing is to be replaced, replace as an assembly.
- Remove the four bolts from the end of the rack cylinder housing and slide the cylinder housing off of the rack.
- Remove the O-ring, back-up ring, steering rack bushing A and cylinder spring from the cylinder housing. Remove the end seal from the cylinder housing. Try to use your fingers so as not to damage the housing.
- Remove the cylinder, cylinder seal retainer, cylinder cap and steering rack from the housing. Remove the retainer washer from the gear housing.
- Remove the four 6mm flange bolts and remove the gear housing cap, pinion seal and O-ring from the gear housing.
- Check the upper pinion bearing for free-play, if excess free-play is evident replace the bearing.
- Remove the cylinder and seal retainer from the rack. Remove the O-rings and circlip from the seal retainer then remove the cylinder cap from the seal retainer.
- Remove the bushing stopper and cylinder end seal from the seal retainer. Carefully pry the piston seal ring from the rack.
- Inspect all sliding surfaces for signs of wear.
- Inspect the rack for broken teeth.
- Inspect the pinion assembly for broken teeth.
- Inspect the main housing, cylinder and seal retainer for any signs of wear.
- Replace all O-rings. Replace any damaged snaprings. Check all bearings for excessive free-play, replace any that are damaged.
- Lubricate all sliding pieces with power steering fluid before assembly, unless otherwise noted.
- Install a new O-ring on the rack, with its narrow edge facing out.
- Install a piston seal guide tool, Honda 07GAG-SD40100, or equivalent onto the rack (big end first). Position the new piston seal ring on the tool and slide it onto the big end of the tool and onto the O-ring on the rack. Remove the tool.
- Coat new O-rings with grease and install them on the cylinder cap and slide the cylinder cap onto the seal retainer. Install the circlip onto the seal retainer.
- Grease the sliding surface of the steering rack bushing and install the bushing on the steering rack with the groove facing the steering rack piston.
- Grease the sliding surface of the cylinder end seal and slide it onto the rack with the grooves facing opposite the seal slider. Attach the seal retainer to the rack.
- Push the rack bushing to the seal retainer until the cylinder end seal is seated in the retainer. Install the stopper ring in the groove of the seal retainer.
- Install the retainer washer on the gear housing. Place the gear housing on a work bench and insert the rack and seal retainer assembly into the housing. Coat the inside of the cylinder with power steering fluid and slide it over the rack assembly, press it into the housing until it seats.
- Install the cylinder spring over the rack, then coat the rack bushing with power steering fluid and install it on the spring.
- Coat the inside surface of the cylinder with power steering fluid and install the cylinder end seal with the groove facing out.
- Install the O-ring and back-up ring on the gear housing. Carefully position the cylinder on the gear housing and loosely install the four bolts.
- Install the steering rack into the cylinder housing, be careful not to damage the rack.
- Tighten the cylinder housing bolts to 16 ft. lbs. (22 Nm).
- Press the lower bearing onto the pinion with its shielded side facing down. Apply a light coating of grease and install the correct snapring. Grease the pinion seal and install it on the gear housing using a seal driver.
- Apply grease to the O-ring and install it in the groove in the housing cap. Install the gear housing cap over the pinion and tighten the flange bolts to 8 ft. lbs. (11 Nm).
- Install the valve body on the assembly. Coat the rack guide with grease.
- Install the rack guide assembly into the housing.
- Screw in each of the tie rods to the rack, while holding the lockwasher so that its tabs are aligned with the slots in the rack. Install the stopper washer with the chamfered side facing out.
- Tighten the tie rod securely, then bend the lockwasher back onto the flange.
- Install the bellows over the end of the rack housing and install the retaining clamp.
- Install the tie rod ends on the tie rods and fill the tie rod boots with grease.
- Install the rack into the vehicle and connect the power steering lines. Adjust the rack as needed.