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Exploded View: Removal

WARNING: This page is about a different car, the 2009 Acura MDX, 2008 Acura MDX, and 2007 Acura MDX. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL  ).

    Disassembly 

  2. Remove the boot bands (A) and tie-rod clips (B). Pull the boots away from the ends of the steering gearbox.
    Fig 1: Identifying Boot Bands And Tie-Rod Clips
    G05486463Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Unbend the lock washer (A).
    Fig 2: Identifying Lock Washer
    G05486464Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. 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 3: Identifying Flat Surface Sections Of Steering Rack With Wrench
    G05486465Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove the lock washer (D) and stop washer (E).
  6. Loosen the locknut (A), then remove the rack guide screw (B).
    Fig 4: Identifying Spring, Rack Guide, Gearbox Housing, Locknut And Rack Guide Screw
    G05486466Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Remove the spring (C) and the rack guide (D) from the gearbox housing.
  8. Remove the cylinder lines from the steering gearbox.
    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 5: Identifying Cylinder Lines From Steering Gearbox
    G05486467Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the damper valves (C) and O-rings (D) from the steering gearbox.
    NOTE: Do not loosen the A and B connectors.
    Fig 6: Identifying Damper Valves And O-Rings With Connectors
    G05486468Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
  11. Remove the end plug (A) from the gearbox housing, then remove the self-locking nut (B) from the pinion shaft end.
    Fig 7: Identifying Gearbox Housing Plug And Self-Locking Nut
    G05486469Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Loosen the 16 mm flare nut (A), and remove the return line joint (B).
    Fig 8: Identifying Return Line Joint And Flare Nut
    G05486470Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. 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. Do not try to disassemble the valve body unit.
    Fig 9: Identifying Valve Body Unit And Gasket From Gearbox Housing
    G05486471Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Slide the steering rack all the way towards the valve body end of the gearbox housing.
  15. 15. 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 10: Identifying Rack Stop
    G05486472Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Remove the rack stop (A), rack bushing (B), and steering rack (C) from the steering gearbox.
    Fig 11: Identifying Rack Stop, Rack Bushing And Steering Rack From Steering Gearbox
    G05486473Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the O-ring (A) and cylinder end seal (B) from the rack bushing (C).
    Fig 12: Identifying O-Ring And Cylinder Seal From Rack Bushing
    G05486474Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. 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 13: Identifying Piston Seal Ring And O-Ring
    G05486475Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. 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 14: Identifying Placing On Cylinder Seal
    G05486476Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. 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.
  21. 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 15: Identifying Steering Gearbox
      G05486477Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Reassembly 

  22. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.
  23. 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 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 the piston's O-ring and seal ring as a set.
      Fig 16: Identifying Seal Ring On Piston Seal Ring Guide
      G05486478Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. 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.
  25. 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 17: Identifying Sliding Tool Onto Rack And Over Piston Seal Ring
    G05486479Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Move the piston seal ring sizing tool back and forth several times to make sure the piston seal ring fits snugly in the piston.
  27. 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 18: Identifying Vinyl Tape Around Rack Teeth And Rack
    G05486480Courtesy of AMERICAN HONDA MOTOR CO., INC.
  28. 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 19: Identifying Coating Inside Surface Of Cylinder Seal With Power Steering Fluid
    G05486481Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  30. 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 20: Identifying Multipurpose Grease To Steering Rack Teeth
    G05486482Courtesy of AMERICAN HONDA MOTOR CO., INC.
  31. Insert an appropriate sized deep socket (A) onto the steering rack as shown.
    Fig 21: Identifying Appropriate Sized Deep Socket Onto Steering Rack
    G05486483Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. 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.
  33. Remove the tool, and center the steering rack.
  34. 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 22: Identifying Vinyl Tape Around Rack End Edges
    G05486484Courtesy of AMERICAN HONDA MOTOR CO., INC.
  35. 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 and attachment.
    Fig 23: Identifying Coating Inside Surface Of Cylinder Seal With Power Steering Fluid
    G05486485Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Coat the new O-ring (C) with power steering fluid, and carefully fit it in the groove of the rack bushing.
  37. 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 24: Identifying Rack Bushing Onto Steering Rack
    G05486486Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Remove the vinyl tape from the steering rack, then remove any adhesive residue.
  39. Install the rack stop (A) onto the steering rack so the hole (B) is aligned with the slot (C) on the cylinder housing.
    Fig 25: Identifying Rack Stop Onto Steering Rack Hole
    G05486487Courtesy of AMERICAN HONDA MOTOR CO., INC.
  40. 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 26: Inserting Circlip Into Hole Of Rack Stop
    G05486488Courtesy of AMERICAN HONDA MOTOR CO., INC.
  41. 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 27: Multipurpose Grease To Bearings In Gearbox Housing With Torque Specification
    G05486489Courtesy of AMERICAN HONDA MOTOR CO., INC.
  42. Install the new self-locking nut (A)onto the pinion shaft end, arid tighten to the specified torque.
    Fig 28: Self-Locking Nut Onto Pinion Shaft With Torque Specifications With Torque Specifications
    G05486490Courtesy of AMERICAN HONDA MOTOR CO., INC.
  43. Tighten the flange bolts to the specified torque.
  44. 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.
  45. After tightening, use a drift to stake (A) the end plug shoulder against the gearbox housing.
    Fig 29: Identifying Mark Location
    G05486491Courtesy of AMERICAN HONDA MOTOR CO., INC.
  46. Install the return line joint (A), and tighten the 16 mm flare nut (B) to the specified torque.
    Fig 30: Return Line Joint And Flare Nut With Torque Specification
    G05486492Courtesy of AMERICAN HONDA MOTOR CO., INC.
  47. Coat the new O-rings (A) with power steering fluid, then install the O-rings to the damper valves (B).
    Fig 31: Damper Valves And O-Rings With Torque Specifications
    G05486493Courtesy of AMERICAN HONDA MOTOR CO., INC.
  48. Install the damper valves to the steering gearbox, and tighten the damper valves to the specified torque.
  49. 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 32: Cylinder Lines Nut With Torque Specification
    G05486494Courtesy of AMERICAN HONDA MOTOR CO., INC.
  50. Apply multipurpose grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.
    Fig 33: Identifying Multipurpose Grease To Sliding Surface Of Rack Guide
    G05486495Courtesy of AMERICAN HONDA MOTOR CO., INC.
  51. 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.
  52. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT  ). After adjusting, check that the rack moves smoothly by sliding it right and left.
  53. Install the new stop washer (A) and new 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 34: Lock Washer With Torque Specification
    G05486496Courtesy of AMERICAN HONDA MOTOR CO., INC.
  54. 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.
  55. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
    Fig 35: Identifying Lock Washer
    G05486497Courtesy of AMERICAN HONDA MOTOR CO., INC.
  56. Apply multipurpose grease to the circumference of the rack end joint housing (A).
    Fig 36: Identifying Multipurpose Grease To Circumference Of Rack Joint Housing
    G05486498Courtesy of AMERICAN HONDA MOTOR CO., INC.
  57. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends.
  58. Center the steering rack within its stroke.
  59. 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 37: Identifying Boots And Rack With Tie-Rod Clips
    G05486499Courtesy of AMERICAN HONDA MOTOR CO., INC.
  60. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
  61. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
    Fig 38: Identifying Tabs With Holes Of Band
    G05486500Courtesy of AMERICAN HONDA MOTOR CO., INC.
  62. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincer or equivalent (B).
    Fig 39: Identifying Portion Of Band
    G05486501Courtesy of AMERICAN HONDA MOTOR CO., INC.
  63. Slide the rack right and left to be certain that the boots are not deformed or twisted.
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