Exploded View

Fig 1: Exploded View Of Steering Gearbox With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver Head 07946-MJ00201
• Driver Handle, 480 mm 070GD-0010100
• Piston Seal Ring Guide 07LAG-SM40100
• Piston Seal Ring Sizing Tool 07LAG-SM4020A
• Bearing Driver Attachment, 42 x 47 mm 07746-0010300
• Driver Handle, 15 x 135L 07749-0010000
• Bearing Driver Attachment, 30 07746-0030300
• Oil Seal Driver, 65 mm 07JAD-PL9A100
• Pincers Oetiker 1098, commercially available

Disassembly 

1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL  ).
2. Remove both tie-rod ends from the rack ends.
3. Drill a 4.0 mm (0.158 in) diameter hole about 2.5-3.0 mm (0.098-0.118 in) in depth in the staked points (A) on the end plug (B) and the gearbox housing (C).
   Fig 2: Drilling Diameter Hole In Depth In Staked Points On End Plug And Gearbox Housing

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Remove the end plug (A) from the gearbox housing, then remove the nut (B) from the pinion shaft end.
   Fig 3: Identifying End Plug And Nut

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Remove the boot band (A) and tie-rod clip (B). Pull the boot away from the end of the steering gearbox. Repeat this step for the other side.
   Fig 4: Identifying Boot Band And Tie-Rod Clip

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown in illustration. Do not clamp the cylinder part of the gearbox housing in a vise.
   Fig 5: Identifying C-Clamp And Wooden Blocks

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Unbend the lock washer (A).
   Fig 6: Bending Lock Washer

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew rack end (C) with another wrench. Be careful not to damage the rack surface with the wrench.
   Fig 7: Holding Flat Surface Sections Of Steering Rack With Wrench

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Remove the lock washer (D) and rubber stop (E). Repeat steps  7 thru  9 for the other side.
10. Loosen the locknut (A), then remove the rack guide screw (B).
    Fig 8: Identifying Gearbox Housing Locknut And Rack Guide Screw

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Remove the spring (C) and the rack guide (D) from the gearbox housing.
12. Remove the cylinder lines (A) from the steering gearbox housing (B).
    NOTE: Use a second wrench when loosening the cylinder lines to avoid damage to the fittings on the steering gearbox.
    Fig 9: Identifying Cylinder Lines And Steering Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Remove the connector A, the connector B, and the O-rings (C) from the steering gearbox.
    Fig 10: Identifying Steering Gearbox Connectors And O-Rings

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
15. With ECPS: Remove the ECPS valve motor (A) and O-rings (B).

    Without ECPS 

    Fig 11: Identifying ECPS Valve Motor And O-Rings (Without ECPS)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    With ECPS 

    Fig 12: Identifying ECPS Valve Motor And O-Rings (With ECPS)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. Remove the flange bolts, the valve body unit (C), and gasket (D) from the gearbox housing. Check that the valve turns smoothly by turning the pinion shaft. If any play or roughness is felt, replace the valve body unit with a new part.
17. Wrap vinyl tape (A) over the splines on the pinion shaft.
    Fig 13: Wrapping Vinyl Tape Over Splines On Pinion Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. Separate the valve housing (A) from the pinion shaft/sleeve (B) and valve oil seal (C).
    Fig 14: Identifying Valve Housing, Pinion Shaft/Sleeve And Valve Oil Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
19. Turn the rack stop (A) counterclockwise until the end (B) of the circlip (C) sticks out from the hole (D) in the cylinder housing. Then turn it clockwise to remove the circlip.
    Fig 15: Turning Rack Stop Counterclockwise Until End Of Circlip Sticks Out From Hole In Cylinder Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
20. Remove the rack stop (A), rack bushing (B), and steering rack (C) from the steering gearbox.
    Fig 16: Identifying Rack Stop, Rack Bushing And Steering Rack

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Remove the O-ring (A) and cylinder end seal (B) from the rack bushing (C).
    Fig 17: Identifying O-Ring, Cylinder End Seal And Rack Bushing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.
    Fig 18: Removing Piston Seal Ring And O-Ring Off Rack Piston

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Insert the driver handle (A) and driver head (B), and carefully place them on the cylinder end seal (C) as shown in illustration. Make sure that the driver head is securely positioned on the cylinder end seal.
    Fig 19: Inserting Driver Handle And Driver Head On Cylinder End Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
24. Install the bearing separator (D) on the gearbox housing. Set the steering gearbox in a press so the gearbox housing points upward, then push out the cylinder end seal by pressing on the end of the driver handle and driver head.
25. Remove the steering gearbox from the press, and set a driver extension (A) on the driver handle (B). Place the steering gearbox in a press, then remove the cylinder end seal (C) from the gearbox housing by pressing on the end of the extension.

    Note these items when pressing the cylinder end seal:

    • Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal.
    • Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the gearbox housing.
      Fig 20: Pressing Steering Gearbox And Driver Extension On Driver Handle

      Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Reassembly 

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

    Note these items during reassembly:

    • Do not over expand the resin seal ring. Install the resin seal ring with care so as not to damage them. After installation, make sure you contract the seal ring using the sizing tool.
    • Replace the piston's O-ring and seal ring as a set.
      Fig 21: Identifying O-Ring, Piston Seal Ring And Ring Guide

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
28. 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.
29. Coat the piston seal ring (A) and the inside of the piston seal ring sizing tool (B) with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
    Fig 22: Coating Piston Seal Ring And Inside Of Piston Seal Ring Sizing Tool With Power Steering Fluid

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
30. Move the piston seal ring sizing tool back and forth several times to make sure the piston seal ring seats snugly in groove of the piston.
31. Wrap vinyl tape around the rack teeth and rack end edges, make sure that the vinyl tape is wrapped carefully so that there is no stepped portion.
    Fig 23: Wrapping Vinyl Tape Around Rack Teeth And Rack End Edges

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
32. 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 to damage the lip of the seal with the edges or teeth of the steering rack.
    Fig 24: Installing Cylinder End Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
33. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
34. Apply steering grease to 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 25: Inserting Steering Rack Into Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
35. Insert an appropriate sized socket (A) onto the steering rack as shown in illustration.
    Fig 26: Pressing Cylinder End Seal Into Bottom Of Cylinder

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
36. Install the new 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.
37. Remove the tool, and center the steering rack.
38. 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 that there is no stepped portion.
    Fig 27: Coating Surface Of Tape With Power Steering Fluid

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
39. 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 driver handle (C) and bearing driver attachment (D).
    Fig 28: Pressing Rack Bushing Using Driver Handle And Bearing Driver Attachment

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
40. Coat the new O-ring (E) with power steering fluid, and carefully fit it in the groove of the rack bushing.
41. Install the rack bushing onto the steering rack with the cylinder end seal grooved side toward the piston. Push in the rack bushing with your finger.
    Fig 29: Installing Rack Bushing Onto Steering Rack With Cylinder End Seal Grooved Side Toward Piston

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
42. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
43. Install the rack stop (A) onto the steering rack so the hole (B) is aligned with the slot (C) on the cylinder housing.
    Fig 30: Installing Rack Stop Onto Steering Rack Hole

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
44. Insert the end of the new 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 31: Inserting End Of Circlip Into Hole Of Rack Stop

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
45. Wrap vinyl tape (A) over the pinion shaft/sleeve (B), then coat the vinyl tape with power steering fluid.
    Fig 32: Identifying Vinyl Tape And Pinion Shaft/Sleeve

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
46. Insert the pinion shaft/sleeve and a new valve oil seal (C) into the valve housing (D). Be careful not to damage the valve seal rings (E).
47. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.
48. Press the new valve oil seal (A) into the valve housing with a hydraulic press, bearing driver attachment, and oil seal driver. Check that the pinion shaft/sleeve turns smoothly by hand after installing it.
    Fig 33: Pressing Valve Oil Seal Into Valve Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
49. Apply multipurpose grease to the bearings (A) in the gearbox housing, and install the valve body unit (B) and new gasket (C) by engaging the gears. Note the valve body unit installation position (direction of line connections). Then loosely install the flange bolts and connector bracket (D).

    Without ECPS 

    Fig 34: Multipurpose Grease Applying Area To Bearings In Gearbox Housing With Torque Specifications (Without ECPS)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    With ECPS 

    Fig 35: Multipurpose Grease Applying Area To Bearings In Gearbox Housing With Torque Specifications (With ECPS)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
50. With ECPS: Coat the new O-rings (E) with power steering fluid, then install the O-rings and the ECPS valve motor (F).
51. Coat the new O-rings (C) with power steering fluid, then install the O-rings to connector A and connector B.
    Fig 36: Coating O-Rings With Power Steering Fluid With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
52. Install connector A and connector B to the steering gearbox, and tighten them to the specified torque.
53. 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.
    • Use a second wrench when tightening the cylinder lines to avoid damaging the fittings on the steering gearbox.
      Fig 37: Steering Gearbox And Cylinder Lines With Torque Specifications

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
54. Apply multipurpose grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.
    Fig 38: Identifying Multipurpose Grease Applying Area To Surface Of Rack Guide And Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
55. Remove the old sealant from the rack guide screw (B), and apply new sealant (Loctite 565) to the middle of the threads of the rack guide screw, then install the spring (C), rack guide screw, and locknut (D).
    NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.
56. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT ). After adjusting, check that the rack moves smoothly by sliding it right and left.
57. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown in illustration. Do not clamp the cylinder part of the gearbox housing in a vise.
    Fig 39: Holding Gearbox Housing Using C-Clamp And Wooden Blocks

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
58. Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place.
    Fig 40: Installing Rubber Stop And Lock Washer With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
59. Hold the flat surface sections of the steering rack with one wrench, and tighten rack end with another wrench. Be careful not to damage the rack surface with the wrench.
60. Bend the lock washer (A) back against the flat spots on the rack end joint housing. Repeat steps  58 thru  60 for the other side.
    Fig 41: Bending Lock Washer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
61. Install the nut (A) onto the pinion shaft end, and tighten to the specified torque.
    Fig 42: Pinion Shaft End And Nut With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
62. Tighten the flange bolts on the valve body unit to the specified torque.
63. Remove the old sealant from the end plug (B), and apply new sealant (Loctite 565) all the way around the threads on the end plug, install the end plug onto the gearbox housing, and tighten it to the specified torque.
    NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.
64. After tightening, use a drift to stake (A) the end plug shoulder against the gearbox housing.
    Fig 43: Staking End Plug Shoulder Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
65. Apply a light coat of silicone grease to the boot grooves (A) on the rack ends.
    Fig 44: Applying Light Coat Of Silicone Grease To Boot Grooves On Rack Ends

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
66. Center the steering rack within its stroke.
67. Clean off any grease or contamination from the boot installation groove (A) on the gearbox housing. Install the boot (B) on the rack end with the tie-rod clip (C), and fit the boot end on the housing properly.
    Fig 45: Installing Boot On Rack End With Tie-Rod Clip

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
68. After installing the boot, wipe the grease off the threaded section (D) of the rack end.
69. Install the new boot band by aligning the tabs (A) with the holes (B) of the band.
    Fig 46: Installing Boot Band By Aligning Tabs With Holes Of Band

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
70. Close the ear portion (A) of the boot band (B) with commercially available pincers Oetiker 1098 (C) or equivalent.
    Fig 47: Closing Ear Portion Of Boot Band With Commercially Available Pincers Oetiker 1098 And Equivalent

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
71. Slide the rack right and left to be certain that the boots are not deformed or twisted. Repeat steps  67 thru  71 for the other side.
72. Install both tie-rod ends to the rack ends.
73. Install the steering gearbox (see STEERING GEARBOX INSTALLATION  ).