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Power Steering Gear (Legend): Reassembly

  1. Install new "O" ring onto rack with narrow edge facing out. Coat Pinion Seal Ring Guide (07MAG-SP00100 ) with power steering fluid, and slide it onto rack, big end first. Position new piston seal ring on seal ring guide big end. Push new seal into piston seal ring guide groove so that it sits on top of "O" ring.
  2. Coat piston seal ring and Piston Seal Ring Sizer (07LAG-SM40200 ), with power steering fluid. Slide ring sizer onto rack and over piston seal ring. Rotate ring sizer while moving it up and down to seat piston seal ring. Coat new "O" rings with grease, and install on cylinder cap.
  3. Slide cylinder cap onto seal retainer. Install snap ring and "O" ring onto seal retainer. Grease sliding surface of steering rack bushing "B" and install bushing onto steering rack with groove in bushing facing steering rack piston. Grease sliding surfaces of new cylinder end seal and Cylinder End Seal Slider (07GAG-SD40300 ).
  4. Position seal and back-up ring onto seal slider with groove facing opposite the slider. Grease rack and slide seal slider onto rack past gear tooth section. Remove seal slider from cylinder end seal,and then separate seal slider and remove from rack. Fit seal retainer onto rack.
  5. Push rack bushing "B" toward seal retainer by hand until cylinder end seal is seated in retainer. Fit bushing clamp in groove of seal retainer. Grease steering rack. Install retainer washer into gear housing. Insert seal retainer and rack into gear housing. Coat inside of cylinder with power steering fluid.
  6. Slide cylinder over rack and into gear housing. Press cylinder into gear housing until it seats. Install cylinder spring over rack. Coat rack bushing "A" with power steering fluid and install it onto spring. Wrap end of steering rack with vinyl tape. Coat tape with grease.
  7. Coat inside of cylinder housing with power steering fluid and install cylinder end seal with lip of seal facing towards inside of cylinder. Install "O" ring and back-up ring on gear housing. Carefully position cylinder onto gear housing and loosely install 4 bolts. Remove vinyl tape from steering rack.
  8. Tighten cylinder housing-to-gear housing bolts to specification. See TORQUE SPECIFICATIONS - LEGEND  table at end of article. Carefully insert rack into cylinder housing without damaging rack sliding surface. Install pinion shaft into pinion holder. Install snap ring in pinion holder groove with tapered side facing out. Grease new "O" ring, and place it in groove in gear housing cap. Install gear housing cap.
  9. Install new "O" ring on rack guide screw. Coat rack guide with grease. Install rack guide, spring and rack guide screw on gear housing. Tighten rack guide screw until it compresses spring and seats against rack guide, and then loosen screw.
  10. Retighten rack guide screw to 36 INCH lbs. (4 N.m), and then loosen it about 25 degrees. Install lock nut on rack guide screw. Tighten lock nut while holding rack guide screw using Lock Nut Wrench (07916-SA50001 ). Grease and install new valve body "O" rings. Install valve body orifices. Use Pinion Seal Guide (07974-SA50600 ) to cover pinion shaft.
  11. Coat pinion holder with grease, and install valve body unit. Remove seal guide. Install new stop washer in groove of steering rack end. See Figure. Install and tighten steering rack end. Stake 2 sections of stop washer. Apply steering grease to outside rack end housing. Install tie rod dust boots and clamps. Position dust boot clamps so locking tab faces up and slightly forward
  12. Bend locking tabs on dust boot clamps, and lightly tap on doubled over portions to reduce clamp height. Install tie rods. To complete installation, reverse removal procedure. Fill pump reservoir with Honda power steering fluid. Start engine, and run it at fast idle. Turn steering wheel lock-to-lock several times to bleed air from system. Add fluid as necessary. Check for leaks.
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