Exploded View

Fig 1: Exploded View Of Steering Gearbox With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Cylinder end seal remover attachment 07TAF-SZ50100
• Valve seal ring sizing tool 07NAG-SR3090A
• Sleeve seal ring guide 07YAG-S2X0100
• Sleeve seal ring sizing tool, 36 mm 07ZAG-S5A0100
• Attachment, 28 x 30 mm 07946-1870100
• Driver 07749-0010000
• Piston seal ring guide 07LAG-SM40100
• Piston seal ring sizing tool 07HAG-SF1020A or 07HAG-SF10200
• Cylinder end seal slider 07LAG-SM40300
• Pincers Oetiker 1098 or equivalent, commercially available
  NOTE: Refer to the Exploded View as needed during this procedure.

Removal 

1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL  ).

   Disassembly 

2. Remove the boot bands (A) and tie-rod clips (B). Pull the boot away from the ends of the steering gearbox.
   Fig 2: Identifying Boot Bands And Tie-Rod Clips

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Unbend the lock washers (A).
   Fig 3: Unbending Lock Washers

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Hold the flat surface sections (A) of the steering rack (B) with a wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench.
   Fig 4: Removing Rack Ends

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Remove the lock washer (D) and stop rubber (E).
6. Loosen the locknut (A), then remove the rack guide screw (B).
   Fig 5: Identifying Locknut, Rack Guide Screw, Spring And Disc Washer

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Remove the spring (C), disc washer (D) and the rack guide (E) from the gearbox housing.
8. Remove the cylinder lines (A) and return line joint (B) from the gearbox.
   Fig 6: Identifying Cylinder Lines And Return Line Joint

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
10. Remove the two flange bolts, then remove the valve body unit (A) from the gearbox (B). Remove the O-ring (C).
    Fig 7: Identifying Valve Body Unit, Gearbox And O-Ring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Wrap vinyl tape (A) around the rack end and cylinder end to prevent metal shavings from entering the cylinder side on the gearbox housing.
    Fig 8: Identifying Vinyl Tape Around Rack End And Cylinder End

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
12. Drill a 4 mm (0.16 in.) diameter hole about 2.5-3.0 mm (0.10-0.12 in.) in depth in the staked point (B) on the cylinder. Do not allow metal shavings to enter the cylinder side of the gearbox housing. After removing the cylinder end, remove any burrs at the staked point.
13. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in the vise. Then remove the cylinder end (C).
    Fig 9: Holding Gearbox Housing Using C-Clamp

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Install a commercially available bearing separator (A) in the gearbox housing as shown.
    Fig 10: Installing Bearing Separator In Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. Place an appropriate size deep socket wrench (B) on the steering rack (C).
16. Set the steering gearbox in a press so the gearbox housing side points upward, then press the cylinder end seal (D) and steering rack out of the gearbox. Hold the steering rack to keep it from falling when pressed clear. Be careful not to damage the inner surface of the cylinder side on the gearbox housing with the tool.
17. 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 11: Removing Seal Ring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. Turn the cylinder end seal remover attachment so it will fit through the rack guide hole of the steering gearbox, then position the seal remover on the cylinder end seal (A). Make sure that the seal remover is securely positioned on the seal edges.
    Fig 12: Positioning Seal Remover On Cylinder End Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
19. Insert 24" long, 3/8" drive extension (A), on the cylinder end seal remover attachment. Place the steering gearbox in a press, then remove the cylinder end seal (B) from the gearbox by pressing on the 24" long 3/8" drive 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.
      Fig 13: Removing Cylinder End Seal

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
20. Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft.
    Fig 14: Removing Valve Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Separate the valve housing from the pinion shaft/ valve using a press.
22. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it.
    NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped.
    Fig 15: Checking Inner Wall Of Valve Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Check for wear, burrs, and other damage to the edges of the grooves in the sleeve.
    NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.
    Fig 16: [Identifying Damage Edges Of Grooves In Sleeve]

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
24. Remove the snap ring (A) and sleeve (B) from the pinion shaft.
    Fig 17: Identifying Snap Ring And Sleeve

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
25. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.
    Fig 18: Identifying Seal Rings

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
26. Using a cutter or an equivalent tool, cut the valve seal ring (A) and the O-ring (B) at the cutting groove position (C) in the pinion shaft. Remove the valve seal ring and the O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and the O-ring.
    Fig 19: Identifying Valve Seal Ring And O-Ring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
27. Remove the valve oil seal (A) and the wave washer (B) from the pinion shaft.

    Note these items during disassembly:

    • Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play or wear, replace the pinion shaft and sleeve as an assembly.
    • The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.
      Fig 20: Identifying Valve Oil Seal, Ball Bearing And Wave Washer

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
28. Remove the valve oil seal (A) and the roller bearing (B) out of the valve housing using a hydraulic press and an appropriate size socket wrench.
    Fig 21: Removing Valve Oil Seal And Roller Bearing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
29. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in the solvent.

    Reassembly 

30. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with power steering fluid.
    Fig 22: Identifying Vinyl Tape On Stepped Portion Of Pinion Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
31. Install the wave washer (B).
32. Coat the inside surface of a new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). Remove the vinyl tape.
33. Apply vinyl tape (A) to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with power steering fluid.
    Fig 23: Applying Vinyl Tape To Splines And Stepped Portion Of Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
34. Fit a new O-ring (B) in the groove of the pinion shaft. Then slide a new valve seal ring (C) over the shaft and in the groove on the pinion shaft.
35. Remove the tape, and apply power steering fluid to the surface of the valve seal ring (A).
    Fig 24: Applying Power Steering Fluid To Surface Of Valve Seal Ring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
36. Apply power steering fluid to the inside of the valve seal ring sizing tool. Set the larger diameter end of the sizing tool over the valve seal ring, and move the sizing tool up and down several times to make the valve seal ring fit in the pinion shaft groove.
37. Remove the sizing tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fit snugly in the pinion shaft groove.
38. Apply power steering fluid to the surface of the sleeve seal ring guide. Slip two new seal rings (A) over the ring guide from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B).

    Note these items when installing the seal ring:

    • Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal rings using the sizing tool.
    • There are two types of sleeve seal rings; black and brown. Do not mix the different types of rings as they are not compatible.
      Fig 25: Identifying Seal Rings

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
39. Align the ring guide with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.
40. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the sleeve seal ring sizing tool, then slowly insert the sleeve into the sizing tool.
    Fig 26: Inserting Sleeve Into Sizing Tool

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
41. Move the sleeve back and forth several times to make the seal rings fit snugly in the sleeve. Make sure the seal rings are not twisted.
42. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve.
    Fig 27: Identifying Pinion Shaft Power Steering Fluid Applying Area

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
43. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and driver. Install the seal with its grooved side facing the tool.
    Fig 28: Installing Seal In Valve Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
44. Press the roller bearing (C) into the valve housing with a hydraulic press and attachment.
45. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid.
    Fig 29: Identifying Vinyl Tape On Pinion Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
46. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C).
47. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.
48. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/ sleeve turns smoothly by hand after installing it.
    Fig 30: Pressing Pinion Shaft/Sleeve Into Valve Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
49. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.
50. Position a new O-ring (A) and a new piston seal ring (B) on the ring guide, 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 sizing tool.
    • Replace piston's O-ring and seal ring as a set.
      Fig 31: Positioning O-Ring And Piston Seal Ring On Ring Guide

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
51. 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. Remove the piston seal ring guide.
52. Coat the piston seal ring (A) and the inside of the piston seal ring sizing tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
    Fig 32: Sliding Tool Onto Rack

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
53. Move the sizing tool back and forth several times to make the piston seal ring fit snugly in the piston.
54. Coat the sliding surface of the cylinder end seal slider (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the special tool With its grooved side (C) facing opposite the special tool.
    Fig 33: Placing Seal On Special Tool

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
55. Coat the surface of the steering rack (A) with power steering fluid.
    Fig 34: Installing Cylinder End Seal Onto Steering Rack

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
56. Install the cylinder end seal (B) onto the steering rack with its grooved side (C) toward the piston (D).
57. Separate the cylinder end seal from the cylinder end seal slider, then remove the seal slider.
58. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C).
    Fig 35: Installing Backup Ring On Steering Rack

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
59. 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 36: Identifying Steering Rack Teeth Steering Grease Applying Area

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
60. Insert an appropriate size socket wrench (A) onto the steering rack as shown.
    Fig 37: Installing Cylinder End Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
61. 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.
62. Remove the tool, and center the steering rack.
63. Coat the sliding surface of the cylinder end seal slider (A) and a new cylinder end seal (B) with power steering fluid. Place the seal on the seal slider with its grooved side (C) facing opposite the seal slider.
    Fig 38: Placing Seal On Seal Slider

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
64. Coat the inside surface of the cylinder end seal slider and steering rack with power steering fluid, then install the cylinder end seal (A) onto the steering rack with its grooved side toward the cylinder.
    Fig 39: Identifying Cylinder End Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
65. Separate the cylinder end seal from the seal slider, then remove the seal slider.
66. Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.
67. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B). Do not clamp the cylinder part of the gearbox housing in the vise.
    Fig 40: Holding Gearbox Housing Using C-Clamp

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
68. Coat the inside surface of the cylinder end (A) with power steering fluid.
    Fig 41: Identifying Inside Surface Of Cylinder End

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
69. Install the cylinder end by screwing it into the cylinder (A). Tighten the cylinder end to the specified torque.
    Fig 42: Cylinder With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
70. Stake the point of the cylinder shown (opposite from where the stake was removed during disassembly).
71. Coat a new O-ring (A) with steering grease, and carefully fit it on the valve housing.
    Fig 43: O-Ring, Needle Bearing And Valve Body Unit With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
72. Apply steering grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections).
73. Tighten the flange bolts (D) to the specified torque.
74. Install the cylinder lines (A) and return line joint (B).

    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.
      Fig 44: Cylinder Lines And Return Line Joint With Torque Specifications

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
75. Apply steering grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.
    Fig 45: Identifying Rack Guide, Rack Guide Screw And Disc Washer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
76. Remove the old sealant from the rack guide screw (B), then apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads. Install the disc washer (C) with its convex side facing the rack guide, the spring (D), the rack guide screw and the locknut (E).
77. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT  ). After adjusting, check that the rack moves smoothly by sliding it right and left.
78. Install a new stop rubber (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. Repeat this step for the other side of the rack.
    Fig 46: Stop Rubber, Lock Washer And Rack End With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
79. Hold the flat surface sections (F) of the steering rack with a wrench, and tighten both rack ends. Be careful not to damages the rack surface with the wrench.
80. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
    Fig 47: Bending Lock Washer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
81. Apply multipurpose grease to the circumference of the rack end joint housing (A).
    Fig 48: Identifying Rack End Joint Housing Grease Applying Area

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
82. Apply a light coat of silicone grease (P/N 08798-9013) to the boot grooves (B) on the rack end.
83. Center the steering rack within its stroke.
84. Clean off any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.
    Fig 49: Identifying Boots And Tie-Rod Clips

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
85. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
86. Install a new boot bands by aligning the tabs (A) with the holes (B) on the band.
    Fig 50: Identifying Boot Bands Tabs

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
87. Close the ear portion (A) of the band (B) with commercially available pincers, Oetiker 1098 or equivalent (C).
    Fig 51: Closing Ear Portion Of Band

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
88. Slide the rack right and left to be certain that the boots are not deformed or twisted.
89. Reinstall the steering gearbox (see STEERING GEARBOX INSTALLATION  ).