gearbox ACURA RL KA9 1996 Service Repair Manual

Lubrication Points

For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work

procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22
LUBRICATION POINTS

Engine

Transmission

Brake line (Includes ABS line)

Power steering gearbox

Steering boots

Throttle cable end

Steering ball joints

Shift lever (Automatic transmission)

Pedal linkage

Intermediate shaft

Brake master cylinder pushrod

Fuel
fill
lid

Battery terminals

Trunk hinges and latch

Door hinges upper and lower

Door opening detents

Hood hinges and hood latch

Brake line joints (Front and rear wheelhouse)

Caliper Piston boot, caliper

Pins and boots

Power steering system

Differential

A/C compressor

API SERVICE LABEL API CERTIFICATION SEAL
LUBRICANT

API Service Grade: Use SJ "Energy Conserving" grade oil.

The oil container may also display the API Certification

seal shown below. Make sure it says "For Gasoline

Engines."

SAE Viscosity: See chart below.

Honda ATF-Z1 (ATF)*1

Genuine Honda DOT3 brake fluid*2

Steering grease P/N 08733 - B070E

Multi-purpose grease

Honda White Lithium Grease

Rust preventive

Silicone grease

Genuine Honda power steering fluid*3

Hypoid gear Oil API GL4 or GL5

Viscosity:

at above -18°C (0°F): SAE 90

at less than -18°C (0°F): SAE 80W-90

Compressor oil:

DENSO: ND-OIL8 (P/N) 38897 - PR7 - A01 AH or 38899 -

PR7-A01)

(For Refrigerant: HFC-134a (R-134a))

Recommended engine oil

viscosity for ambient

temperature ranges

*1: Always use Honda ATF-Z1 (ATF). Using a non-Honda ATF can affect shift quality.

*2: Always use Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the

life of the system.

*3: Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmis-

sion fluid can cause increased wear and poor steering in cold weather.ProCarManuals.com

Transmission
Removal (cont'd )
20. Disconnec t th e transmissio n rang e switc h connector ,
the n remov e th e clam p fro m th e harnes s bracket .
CLAMP
HARNES SBRACKE T
TRANSMISSIO N RANG E
SWITC H CONNECTO R
21. Remov e th e lowe r plate , an d reinstal l th e steerin g
gearbo x mountin g bolt s a s shown .
STEERIN G GEARBO X
STEERING GEARBO XMOUNTING BOLT S
Reinstal l thes e bolt s o n
th e steerin g gearbox .
LOWERPLATE
22. Remov e th e shif t cabl e guid e bracke t fro m th e
transmissio n beam .
CAUTION : Tak e car e no t t o ben d th e shif t cable .
TRANSMISSIO N
REA R MOUN T
BRACKET/MOUN T
EXHAUST PIP EBRACKE T
TRANSMISSIO NBEAM
23. Plac e a jac k unde r th e transmission , an d rais e th e
transmissio n jus t enoug h t o tak e weigh t of f o f th e
mounts , the n remov e th e transmissio n beam , rea r
transmissio n bracket/moun t an d exhaus t pip e bracket .
24. Mak e sur e th e transmissio n i s i n position , the n
remov e th e 3 6 m m sealin g bol t an d O-rin g ('0 0
model ) fro m th e secondar y drive n gea r shaft .
NOTE : I f th e transmissio n is in an y positio n othe r tha n
shift int o positio n b y rotatin g th e contro l shaft .
36 m m SEALIN G BOL T
O-RIN GReplace .'00 mode l
EXTENSIO N SHAF T
PULLE R07LAC-PW5010 1
25. Remov e th e extensio n shaf t fro m th e differentia l
usin g th e specia l too l a s shown .
SHIFT CABL EGUIDE
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STEERING WHEE L
Remova l an d Installation , pag e 17-1 8
Disassembly/Reassembly , pag e 17-1 9
DRIVER' S AIRBA G ASSEMBL Y
Removal/Installation , se e sectio n 2 4
Inde x
NOTE :
• I f a n intac t airba g assembl y ha s bee n remove d fro m a scrappe d vehicl e o r ha s bee n foun d defectiv e o r damage d dur -
in g transit , storag e o r service , i t shoul d b e deploye d (se e sectio n 24 ).
• Befor e removin g th e gearbox , remov e th e driver' s airba g assembl y an d steerin g wheel .
• Afte r installin g th e gearbox , chec k th e whee l alignmen t an d adjus t i t i f necessary .
SR S component s ar e locate d in thi s area . Revie w th e SR S componen t locations , precautions , an d procedure s i n th e SR S
( sectio n 24 ) befor e performin g repair s o r service .
Componen t Location s
RESERVOI RFluid Replacement , pag e 17-1 6
Flui d Leakag e Inspection , pag e 17-2 3
POWE R STEERIN G PUM P
Pum p Bel t Inspectio n an d
Adjustment , pag e 17-1 5
Pum p Pressur e Check , pag e 17-1 7
Removal/Installation , pag e 17-2 4
Disassembly , pag e 17-2 5
Inspection , pag e 17-2 6
Reassembly , pag e 17-2 8
POWE R STEERIN G SPEE D SENSO R
Replacement , pag e 17-1 3
STEERIN G GEARBO XRack Guid e Adjustment , pag e 17-1 6
Removal , pag e 17-3 0
Disassembly , pag e 17-3 2
Reassembly , pag e 17-4 0
Installation , pag e 17-5 1
VALV E BOD Y UNI T
Overhaul , pag e 17-3 6 TIE-RO
D EN D BAL L JOIN T
Bal l Join t Boo t Replacement ,
pag e 17-5 3
STEERIN
G COLUM N
Removal/Installation , pag e 17-2 0
Inspection , pag e 17-2 1
Steerin g Loc k Replacement , pag e 17-2 2
Inspectio n fo r Drivin g Positio nMemory Syste m (DPMS), see sectio n 2 3CABL E REE LRemoval/Installation ,
se e sectio n 2 4
IGNITIO N SWITC HInspectio n an d Replacement ,
se e sectio n 2 3
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Troubleshooting
General Troubleshootin g (cont'd )
Assist (excessivel y ligh t steering ) a t
hig h speed .
Shoc k o r vibratio n whe n whee l i s
turne d to ful l lock .
Steerin g whee l wil l no t retur n
smoothly .
If th e proble m is no t correcte d b y
adjustin g th e rac k guide , replace
th e gearbox .
I
f th e measurement s ar e ou t o f
specifications , adjus t th e rac k
guide .
Whee
l alignmen t i s normal .
Chec k th e steerin g whee l opera -
tio n an d powe r assis t chec k (se e
pag e 17-12 ).
A
an d B cylinde r line s ar e nor -
mal , chec k whee l alignmen t (se e
sectio n 18 ). Whee
l alignmen t i s abnormal ,
adjus t a s needed .
A
o r B cylinde r lin e i s deformed ;
replac e it .
Chec
k cylinde r line s A an d B fo r
deformation .
Chec
k th e rac k guid e fo r prope r
adjustmen t (se e pag e 17-16 ).
Chec k th e rac k guid e fo r prope r
adjustmen t (se e pag e 17-16 ).
Rac k guid e is adjuste d properly .
Chec k th e bel t fo r slippag e an d
adjus t a s necessar y (se e pag e
17-15 ).
If th e proble m is no t correcte d b y
adjustin g th e rac k guide , adjus t
th e fron t whee l alignmen t (se e
sectio n 18 ).
Rac k guid e wa s backe d of f exces -sively.
Adjus t th e rac k guide .
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Install th e powe r steerin g pressur e
gauge . Clos e th e pressur e contro l
valv e full y an d measur e th e pum p
pressur e (se e pag e 17-17 ). Adjus
t bel t tensio n (se e pag e
17-15 ) o r replac e belt .
Adjus
t rac k guid e (se e pag e 17-16 ).
I f th e proble m is no t correcte d b y
adjustin g th e rac k guide , replac e
th e gearbox .
Adjus t bel t tension . Replac e th e
belt , i f necessar y (se e pag e 17-15 ).
I f th e engin e stall s whe n th e whee l
i s turne d whil e th e vehicl e i s
stoppe d o r movin g a t lo w speed ,
adjus t idl e spee d (se e sectio n 11 ).
Chec k powe r steerin g flui d level . I f
leve l i s excessivel y low , chec k fo r
leak s i n th e system . Ad d flui d t o
th e specifie d level .
I f flui d leve l i s OK , chec k O-ring s
an d seal s o n bot h end s o f th e
pum p inle t hose , an d th e P/ Spum p housin g matin g surface s
an d driv e shaf t oi l sea l fo r suctio n
leaks . Replac e part s a s necessary .
Chec k i f pum p pressur e i s withi n
th e rang e 7,80 0 - 8,80 0 kP a (8 0 - 9 0
kgf/cm
2, 1,13 8 - 1,28 0 psi ) an d th e
gaug e needl e trave l i s 50 0 kP a ( 5
kgf/cm
2, 7 1 psi ) o r less . Chec k th e
flo w contro l valv e i f th e needl e
trave l exceed s 50 0 kP a ( 5 kgf/cm
2,
7 1 psi) . I f th e flo w contro l valv e i s
normal , replac e th e pum p a s a n
assembly .
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Steering Linkage and Gearbox
Inspection and AdjustmentProCarManuals.com

2. Tighte n th e rac k guid e scre w to 2 5 N- m (2. 5 kgf-m ,
18lbf-ft) , the n loose n it .
3 . Retighte n th e rac k guid e scre w to 5. 9 N- m (0. 6 kgfm ,
4 Ibf-ft) , the n bac k it of f t o specifie d angle .
Specifie d Retur n Angle : 1 5 ± 5°
4 . Tighte n th e locknu t whil e holdin g th e rac k guid e
screw .
5 . Chec k fo r tigh t o r loos e steerin g throug h th e com -
plet e turnin g travel .
6 . Perfor m th e followin g inspection s (se e pag e 17-12 ).
• Steerin g operation .
• Powe r assis t wit h vehicl e parked . 2
. Connec t a hos e o f correc t diamete r t o th e discon -
necte d retur n hose , an d pu t th e hos e en d i n a suit -
abl e container .
CAUTION : Tak e car e no t t o spil l th e flui d o n th e
bod y an d parts . Wip e of f an y spille d flui d a t once .
3 . Star t th e engine , le t i t ru n a t idle , an d tur n th e steer -
in g whee l fro m lock-to-loc k severa l times . Whe n
flui d stop s runnin g ou t of the hose , shu t of f th e
engine . Discar d th e fluid .
4 . Reinstal l th e retur n hos e o n th e reservoir .
5 . Fil l th e reservoi r t o th e uppe r leve l line .
6 . Star t th e engin e an d ru n i t a t fas t idle , the n tur n th e
steerin g fro m lock-to-loc k severa l time s t o blee d ai r
fro m th e system .
7 . Rechec k th e flui d leve l an d ad d mor e if necessary .
CAUTION : D o no t fil l th e reservoi r beyon d th e
uppe r leve l line .
Inspectio n an d Adjustmen t
Rack Guid e Adjustmen t
NOTE: Perfor m rac k guid e adjustmen t wit h th e wheel s
i n th e straigh t ahea d position .
1 . Loose n th e rac k guid e scre w locknu t wit h th e spe -
cial tool .
'96 - 9 8 models :
Loose n th e rac k guid e screw .
'9 9 - 0 1 models :
Remov e th e rac k guid e screw . Remov e th e ol d
sealan t fro m th e rac k guid e scre w threade d section ,
an d appl y ne w sealan t t o th e al l aroun d threads .
Loosel y instal l th e rac k guid e scre w o n th e steerin g
gearbox .
Fluid Replacemen t
Check th e reservoi r a t regula r intervals , an d ad d th e rec -
ommende d flui d a s necessary .
CAUTION : Alway s us e Genuin e Hond a Powe r Steerin g
Fluid- V o r S . Usin g an y othe r typ e o f powe r steerin g
flui d o r automati c transmissio n flui d ca n caus e
increase d wea r an d poo r steerin g in col d weather .
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Pump Pressur e Chec k
Check th e flui d pressur e a s follow s t o determin e
whether th e troubl e i s i n th e pum p o r gearbox .
NOTE: Firs t chec k th e powe r steerin g flui d leve l an d
pum p bel t tension .
CAUTION : Carefull y disconnec t th e high-pressur e hos e
s o th e powe r steerin g flui d doe s no t lea k o n th e fram e
an d othe r parts .
1 . Remov e th e ai r cleane r (ACL) .
2. Disconnec t th e outle t hos e fro m th e pum p outle t fit -
ting , an d instal l th e P/ S join t adapte r (pump ) o n th e
pum p outlet .
P/S JOIN T ADAPTE R (PUMP )
07GAK-SE0011 2
P/S PRESSUR EGAUGE07406-0010001
P/S JOIN T ADAPTE R (HOSE )07GAK-SE0012 0
3. Connec t th e P/ S join t adapte r (pump ) t o th e powe r
steerin g pressur e gauge , the n connec t th e outle t
hose t o th e adapter .
4 . Connec t th e powe r steerin g pressur e gaug e t o th e
adapter .
5 . Ope n th e shut-of f valv e fully .
6 . Ope n th e pressur e contro l valv e fully .
P/S PRESSUR E GAUG E
0740 6-001000 1
7. Star t th e engin e an d le t i t idle .
8 . Tur n th e steerin g whee l fro m lock-to-loc k severa l
times to war m th e flui d to operatin g temperature .
9. Measur e steady-stat e flui d pressur e whil e idlin g
with th e shut-of f valv e full y open . I f th e pum p i s i n
goo d condition , th e gaug e shoul d rea d les s tha n
150 0 kP a (1 5 kgf/cm
2, 21 3 psi) .
I f i t read s high , chec k th e fee d lin e o r valv e bod y
unit.
10. Clos e th e pressur e contro l valve , the n clos e th e shut -
off valv e graduall y unti l th e pressur e gaug e needl e
i s stable . Rea d th e pressure .
11 . Immediatel y ope n th e pressur e contro l valv e fully .
CAUTION : D o no t kee p th e pressur e contro l valv e
close d mor e tha n 5 second s o r th e pum p coul d b e
damage d b y over-heating .
I f th e pum p i s i n goo d condition , th e gaug e shoul d
rea d a t leas t 7,80 0 - 8,80 0 kP a (8 0 - 9 0 kgf/cm
2, 1,13 8
- 1,28 0 psi) . A lo w readin g mean s pum p outpu t i s
to o lo w fo r ful l assist . Repai r o r replac e th e pump .
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Power Steering Gearbox

Removal (cont'd)

12. Disconnect the three lines (sensor inlet line, 10 mm

return line and 6 mm return line) from the hoses.

CAUTION: After disconnecting the line, plug or

seal the line with a piece of tape or equivalent.

13. Remove the mounting brackets and steering gear-

box.

NOTE: Before removing the steering gearbox, place

a jack stand under the gearbox to support it.

CAUTION: Be careful not to bend or damage fluid

lines when removing the steering gearbox.ProCarManuals.com

Disassembly
Steering Rac k Disassembl y
NOTE:
• Befor e disassemblin g th e gearbox , was h i t of f wit h
solven t an d a brush .
• D o no t di p seal s an d 0-ring s i n solvent .
1 . Remov e th e steerin g gearbo x (se e pag e 17-30 ).
2 . Remov e th e bot h tie-ro d ends .
3 . Remov e th e thre e line s (senso r inle t line , 1 0 m m
retur n lin e an d 6 m m retur n line ) fro m th e valv e bod y
unit.
4. Remov e th e lin e mountin g cushions .
Power Steerin g Gearbo x
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