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Steering Gearbox Overhaul: Reassembly

WARNING: This page is about a different car, the 2006 Honda Odyssey and 2005 Honda Odyssey. However, it is still accessible from the selected car via links, so may be relevant.
  1. Coat the special tool with power steering fluid, then slide it onto the rack, big end first.
  2. Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool.
    NOTE: 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 special tool (sizing tool).
    • Replace the piston's O-ring and seal ring as a set.
    Fig 1: Positioning O-Ring And Piston Seal Ring On Special Tool
    G03705351Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. 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.
  4. Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
    Fig 2: Coating Piston Seal Ring And Inside Of Special Tool With Power Steering Fluid
    G03705352Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Move the special tool back and forth several times to make sure the piston seal ring fits snugly in the piston.
  6. 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 3: Wrapping Vinyl Tape Around Rack Teeth
    G03705353Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. 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 4: Coating Inside Surface Of Cylinder End Seal With Power Steering Fluid
    G03705354Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  9. 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 5: Applying Multipurpose Grease To Steering Rack Teeth
    G03705355Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Insert a deep socket (A) onto the steering rack as shown in Fig 6 .
    Fig 6: Inserting Deep Socket Onto Steering Rack
    G03705356Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. 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.
  12. Remove the tool, and center the steering rack.
  13. 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 there is no stepped portion.
    Fig 7: Wrapping Vinyl Tape Around Rack End Edges
    G03705357Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. 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 special tools.
    Fig 8: Coating Inside Surface Of Cylinder End Seal With Power Steering Fluid
    G03705358Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Coat the new O-ring (C) with power steering fluid, and carefully fit it in the groove of the rack bushing.
  16. 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 9: Installing Rack Bushing Onto Steering Rack
    G03705359Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  18. Install the rack stop (A) onto the steering rack so the hole (B) is aligned with the slot (C) on the cylinder housing.
    Fig 10: Installing Rack Stop Onto Steering Rack
    G03705360Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Insert the end of the 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 11: Inserting End Of Circlip Into Hole Of Rack Stop
    G03705361Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. 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 12: Applying Grease To Bearings In Gearbox Housing
    G03705362Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the new self-locking nut (A) onto the pinion shaft end, and tighten to the specified torque.
    Fig 13: Installing Self-Locking Nut Onto Pinion Shaft End
    G03705363Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Tighten the flange bolts to the specified torque.
  23. Apply new sealant (Loctite 565) all the way around the threads on the end plug (B), install the end plug onto the gearbox housing, and tighten it to the specified torque.
  24. After tightening, use a drift to stake (A) the end plug shoulder against the gearbox housing.
    Fig 14: Using Drift To Stake End Plug Shoulder Against Gearbox Housing
    G03705364Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. 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.
    NOTE: Use a second wrench when tightening the cylinder lines to avoid damaging the fittings on the steering gearbox.
    Fig 15: Installing Cylinder Lines
    G03705365Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Apply multipurpose grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.
    Fig 16: Applying Multipurpose Grease To Sliding Surface Of Rack Guide
    G03705366Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Apply new sealant (Loctite 565) all the way around the first three threads of the rack guide screw (B), then install the spring (C), rack guide screw, and locknut (D).
  28. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT  ). After adjusting, check that the rack moves smoothly by sliding it right and left.
  29. Install the new stop washer (A) and lock washer (B). Align the lock washer tabs (C) with the slots (D). Install the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.
    Fig 17: Installing Stop Washer And Lock Washer
    G03705367Courtesy of AMERICAN HONDA MOTOR CO., INC.
  30. Hold the flat surface sections of the steering rack with a wrench, and tighten both rack ends. Be careful not to damage the rack surface with the wrench.
  31. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
    Fig 18: Bending Lock Washer Back Against Flat Spot On Rack End Joint Housing
    G03705368Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. Apply multipurpose grease to the circumference of the rack end joint housing (A).
    Fig 19: Applying Multipurpose Grease To Circumference Of Rack End Joint Housing
    G03705369Courtesy of AMERICAN HONDA MOTOR CO., INC.
  33. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends.
  34. Center the steering rack within its stroke.
  35. Clean off any grease or contamination from the boot installation surfaces (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 20: Installing Boot On Rack Ends With Tie-Rod Clips
    G03705370Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
  37. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
    Fig 21: Installing Boot Bands By Aligning Tabs With Holes Of Band
    G03705371Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincer or equivalent (B).
    Fig 22: Closing Ear Portion Of Band
    G03705372Courtesy of AMERICAN HONDA MOTOR CO., INC.
  39. Slide the rack right and left to be certain that the boots are not deformed or twisted.
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