Exploded View

Fig 1: Exploded View Of Steering Gearbox

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver Handle, 480 mm 070GD-0010100
• Driver Head 07946-MJ00201
• Piston Seal Ring Guide 07LAG-SM40100
• Piston Seal Ring Sizing Tool 07LAG-SM4020A
• Driver Handle, 15 x 135L 07749-0010000
• Bearing Driver Attachment, 42 x 47 mm 07746-0010300
• Bearing Driver Attachment, 30 mm I.D. 07746-0030300
• Oil Seal Driver, 65 mm 07JAD-PL90100
• Pincers Oetiker 1098, commercially available

Disassembly 

1. Remove the steering gearbox 
2. Remove the tie-rod end from the rack end.
3. Drill a 4.0 mm (0.16 in) diameter hole about 2.5-3.0 mm (0.10-0.12 in) in depth in the staked points (A) on the end plug (B) and the gearbox housing (C).
   Fig 2: Drilling Diameter Hole 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 bands (A) and tie-rod clips (B). Pull the boot away from the ends of the steering gearbox.
   Fig 4: Identifying Boot Bands And Tie-Rod Clips

   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. Do not clamp the cylinder part of the gearbox housing in a vise.
   Fig 5: Holding Gearbox Housing Using C-Clamp And Wooden Blocks

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Unbend the lock washer (A).
   Fig 6: Unbending 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 both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench.
   Fig 7: Removing Steering Rack

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

    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 (C) from the steering gearbox housing (D).
    NOTE: Use a second wrench when loosening the cylinder lines to avoid damage to the fittings on the steering gearbox. Do not loosen the A and B connectors.
    Fig 9: Removing Cylinder Lines From Steering Gearbox

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Remove the damper valves (C) and O-rings (D) from the steering gearbox.
    NOTE: Do not loosen the A and B connectors.
    Fig 10: Identifying Damper Valves And O-Rings With Connector

    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. Loosen the 16 mm flare nut (A), and remove the return line joint (B).
    Fig 11: Identifying Flare Nut And Return Line Joint

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. Remove the two flange bolts, the valve body unit (A), and gasket (B) 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.
    Fig 12: Identifying Valve Body Unit And Gasket With Mounting Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Apply vinyl tape (A) to the splines on the pinion shaft.
    Fig 13: Applying Vinyl Tape To 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

    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 Seal Ring

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Insert the driver handle and driver head, and carefully place them on the cylinder end seal (A) as shown. Make sure that the driver head is securely positioned on the cylinder end seal.
    Fig 19: Pressing Cylinder Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
24. Install the bearing separator (B) 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. Place the steering gearbox in a press, then remove the cylinder end seal (B) 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: Removing Cylinder Seal From Gearbox Housing

    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, 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: Installing Piston Seal Ring

    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 with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
    Fig 22: Sliding Piston Seal Ring

    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 fits snugly in the piston.
31. 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 23: Wraping Vinyl Tape Around Rack Teeth And Rack

    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 Seal

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
33. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
34. Apply multipurpose 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: Applying Multipurpose Grease To Steering Rack Teeth

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
35. Insert an appropriate sized deep socket (A) onto the steering rack as shown.
    Fig 26: Inserting Appropriate Sized Deep Socket Onto Steering Rack

    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: Wraping Vinyl Tape Around Rack End Edges

    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 and bearing driver attachment.
    Fig 28: Pressing Rack Bushing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
40. Coat the new O-ring (C) 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

    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: Aligning Slot On Cylinder Housing

    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. Apply vinyl tape (A) to the pinion shaft/sleeve (B), then coat the vinyl tape with power steering fluid.
    Fig 32: Applying Vinyl Tape To 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 two flange bolts.
    Fig 34: Applying Multipurpose Grease To Bearings In Gearbox Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
50. Install the nut (A) onto the pinion shaft end, and tighten to the specified torque.
    Fig 35: Identifying Nut And End Plug

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
51. Tighten the flange bolts on the valve body unit to the specified torque.
52. 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.
53. After tightening, use a drift to stake (A) the end plug shoulder against the gearbox housing.
    Fig 36: Identifying End Plug

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
54. Install the return line joint (A), and tighten the 16 mm flare nut (B) to the specified torque.
    Fig 37: Identifying Return Line Joint And Flare Nut

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
55. Coat the new O-rings (A) with power steering fluid, then install the O-rings to the damper valves (B).
    Fig 38: Identifying Damper Valves And O-Rings

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
56. Install the damper valves to the steering gearbox, and tighten the damper valves to the specified torque.
57. 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 39: Identifying Cylinder Lines

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
58. Apply multipurpose grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.
    Fig 40: Identifying Multipurpose Grease Applying Area Onto Sliding Surface Of Rack Guide

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
59. 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.
60. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT ). After adjusting, check that the rack moves smoothly by sliding it right and left.
61. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in a vise.
    Fig 41: Holding Gearbox Housing Using C-Clamp And Wooden Blocks

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
62. 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. Repeat this step for the other side of the rack.
    Fig 42: Installing Steering Rack

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
63. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.
64. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
    Fig 43: Bending Lock Washer

    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: Identifying Light Coat Of Silicone Grease Applying Area On Boot Grooves

    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 grooves (A) on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end on the housing properly.
    Fig 45: Identifying Boot Installation Surfaces On Gearbox Housing

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

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
70. Close the ear portion (A) of the band with pincers Oetiker 1098, commercially available or equivalent (B).
    Fig 47: Closing Portion Of Band

    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.
72. Install the tie-rod end to the rack end.
73. Install the steering gearbox