gearbox ACURA TL 1995 Service User Guide

24. Selec t th e 4 4 m m shim(s) .
NOTE : Onl y reinstal l th e origina l 4 4 m m shim(s ) whe n
th e steerin g gearbo x i s reassemble d withou t replacin g
th e pinio n shaft , valv e housing , an d gearbo x housin g
wit h ne w ones .
I f th e pinio n shaft , valv e housing , an d gearbo x housin g
ar e replaced , selec t th e ne w shim(s ) a s follows .
Shim selection :
a. Se t th e fou r 4 4 m m shim s o n th e bearin g surfac e o f
th e gearbo x housing . Tota l thicknes s o f th e fou r
shim s shoul d equa l n o mor e tha n 0.7 0 mm .
Shi m set : fou r 4 4 m m shim s (Thickness : 0.1 0 mm ,
0.1 5 mm , 0.2 0 mm , 0.2 5 m m respectively )
CAUTION: Th e fou r 4 4 m m shim s d o no t hav e
thicknes s identificatio n marks . Measur e th e thick -
ness o f eac h shi m usin g a micrometer , an d mar k
the shi m fo r identification .
b. Instal l th e valv e bod y uni t o n th e gearbox , an d
tighte n th e flang e bolt s t o th e specifie d torque .
VALVE BOD YUNITFLANG E BOL T20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
SHIM SET(fou r shims )
c. Measur e th e clearanc e betwee n th e gearbo x an d
valv e bod y uni t usin g a feele r gaug e a s shown .
NOTE : Measur e th e clearanc e a t th e poin t midwa y
betwee n th e tw o mountin g bolts .
FEELE R GAUG E
d. Determin e th e require d thicknes s o f th e 4 4 m m
shim s b y subtractin g th e clearanc e obtaine d in th e
ste p - 3 fro m th e tota l thicknes s o f th e fou r shims .
(Tota l thicknes s o f th e 4 shims ) - (Clearance ) =
Require d thicknes s o f th e shim s
NOTE : Selec t th e shim s s o tha t th e tota l thicknes s
i s clos e to , bu t les s tha n th e require d thickness .
Example :
Measuremen t i s 0.2 8 m m (0.01 1 in) :
0.0 7 - 0.2 8 = 0.4 2 m m (0.02 8 - 0.01 1 = 0.01 7 in )
Th e selecte d shim s shoul d b e 0.2 5 m m (0.01 0 in ) an d
0.1 5 m m (0.00 6 in ) i n thickness .
I f th e require d shi m thicknes s i s 0.1 0 m m o r less , n o
shim s ar e necessary .
25 . Se t th e selecte d 4 4 m m shim s o n th e bearin g sur -
fac e o f th e gearbo x housing .
26 . Coa t th e ne w O-rin g wit h grease , an d carefull y fi t i t
o n th e valv e housing .
27 . Appl y greas e t o th e needl e bearin g i n th e gearbo x
housing.
28. Instal l th e valv e bod y uni t o n th e gearbo x housin g
b y engagin g th e gears .
NOTE : Not e th e valv e bod y uni t installatio n posi -
tio n (directio n o f lin e connection) .
29 . Tighte n th e flang e bolt s to th e specifie d torque .
VALVE BOD Y UNI T
FLANG E BOL T20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
44 m m SHIM S(Selecte d numbe r o fshims )
O-RINGReplace .
NEEDLE BEARIN G
ProCarManuals.com

Steering Gearbox

Installation

CAUTION: Be careful not to bend or damage cylinder

lines A and B or the four fluid lines when installing the

gearbox.

1. Install the mount cushion on the right side.

2. Loosely install the mounting bracket on the cushion

with the two gearbox mounting bolts.

MOUNT CUSHION

STEERING GEARBOX

GEARBOX MOUNTING BOLTS

38 N-m (3.9 kgf-m, 28 Ibf-ft)

Loosely install.

3. Center the steering rack within its stroke.
4. Install the steering joint, and reconnect the steering

shaft and pinion shaft.

NOTE: Make sure the steering joint is connected as

follows:

a. Insert the upper end of the steering joint onto the

steering shaft (line up the bolt hole with the flat on

the shaft), and loosely install the upper joint bolt,

b. Slip the lower end of the steering joint onto the

pinion shaft (line up the bolt hole with the

groove around the shaft), and loosely install the

lower joint bolt.

Be sure that the lower joint bolt is securely in the

groove in the pinion shaft,

c. Pull on the steering joint to make sure that the

steering joint is fully seated. Then tighten the

joint bolts.

STEERING JOINT
STEERING JOINT BOLTS

2.2 N-m (2.2 kgf-m, 16 Ibf-ft)

UPPER JOINT BOLT

Bolt must line up

with flat on shaft.

Flat portion.

Groove.
STEERING

SHAFT

PINION

SHAFT
STEERING JOINT

LOWER JOINT BOLT

Bolt must line up with

groove around on shaft.

5. Center the cable reel by first rotating it clockwise

until it stops. Then rotate it counterclockwise

(approximately two turns) until the arrow mark on

the label points straight up.

Reinstall the steering wheel (refer to the '95 - 98

Acura 2.5TL Service Manual, P/N 61SW504):ProCarManuals.com

Front Seat

Seat Linkage (4-way Power Adjustable) Replacement

The slide joint cable, recline motor, slide motor and slide gearbox replacement procedures are the same as the 8-way

power adjustable seat.

NOTE:

Grease the slide lead screws and gear portion of the recline motor.

Check the slide motor, slide gearbox and recline motor operations.

5 x 0.8 mm

3 N-m (0.3 kgf-m,

21 Ibf-ft)

8 x
1.25
mm

14 N-m (1.4 kgf-m,

10 Ibf-ft)

6 x 1.0 mm

8 N-m (0.8 kgf-m,

6 Ibf-ft)
RECLINE

MOTOR

8 x
1.25
mm

14 N-m (1.4 kgf-m,

10 Ibf-ft)

OUTER SLIDE

ADJUSTER

SLIDE

GEARBOX
6 x 1.0 mm

8 N-m (0.8 kgf-m

6 Ibf-ft)

3.7 N-m (0.38 kgf-m,

2.7 Ibf-ft)
PIVOT

BRACKET

6 x 1.0 mm

9 N-m (0.9 kgf-m,

7 Ibf-ft)

Apply liquid

thread lock.
INNER SLIDE

ADJUSTER

10 x
1.25
mm

25 N-m (2.5 kgf-m,

18 Ibf-ft)

SLIDE

MOTOR
6 x 1.0 mm

9 N-m (0.9 kgf-m,

7 Ibf-ft)

Apply liquid thread lock.
SLIDE JOINT

CABLE
Apply liquid thread

lock.
RECLINE ADJUSTERProCarManuals.com

Component Location s
Index
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 steerin g gearbox , remov e th e driver' s airba g assembl y an d steerin g wheel .
• Afte r installin g th e steerin g gearbox , chec k th e whee l alignmen t an d adjus 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 in th e SR S
( sectio n 24 ) befor e performin g repair s o r service .
STEERIN G WHEE LRemoval , pag e 17-2 7
Disassembly/Reassembly , pag e 17-2 8
Installation , pag e 17-2 9
RESERVOI RFluid Replacement , 17-2 4
VALVE BOD Y UNI T
Overhaul , pag e 17-5 2
POWE R STEERIN G SPEE D SENSO R
Replacement , pag e 17-2 1
STEERING COLUM N
Removal , pag e 17-3 1
Inspection , pag e 17-3 3
Installation , pag e 17-3 4IGNITIO N SWITC HSee sectio n 2 3
POWE R STEERIN G PUM P
Pum p Bel t Inspection , pag e 17-2 3
Pum p Bel t Adjustment , pag e 17-2 3
Pum p Pressur e Check , pag e 17-2 5
Removal , pag e 17-3 7
Disassembly , pag e 17-3 7
Reassembly , pag e 17-4 2
Installation , pag e 17-4 6
STEERIN G GEARBO XRack Guid e Adjustment , pag e 17-2 4
Removal , pag e 17-4 7
Disassembly , pag e 17-4 9
Reassembly , pag e 17-5 6
Installation , pag e 17-6 6 TIE-RO
D EN D BAL L JOIN T
Bal l Join t Boo t Replacement , pag e 17-6 9
ProCarManuals.com

System Descriptio n
This powe r steerin g syste m is speed-sensitive . It s mai n component s ar e a mechanica l spee d sensor , a rotar y valve-typ e
gearbox, an d a constan t volume , vane-typ e pump . Th e syste m regulate s th e powe r assis t accordin g to vehicl e speed , roa d
conditions , an d drivin g style . Th e amoun t o f powe r assis t change s linearl y fro m hig h assist , whe n drivin g a t lo w speed s o r
parking , t o lo w assist , whe n drivin g a t hig h speeds .
Fluid Flo w Diagra m
The flui d volum e fro m th e pump , whic h i s drive n b y th e cran k pulley , i s regulate d b y th e flo w contro l valv e buil t int o th e
pump . Th e regulate d flui d i s fe d t o th e valv e bod y uni t locate d outsid e th e pinio n shaf t o f th e steerin g gearbox . Th e flui d i s
regulate d t o th e prope r pressur e b y th e valve s i n th e valv e bod y uni t an d b y th e powe r steerin g spee d senso r befor e it
flow s t o th e powe r cylinder . Th e directio n o f th e flo w is determine d b y th e rotar y valve . Th e flui d the n returns to th e reser -
voi r throug h th e retur n passag e an d i s fe d t o th e pum p again .
To RESERVOI R
VALVE BOD Y UNI T
TORSIO N BA R
INPU T SHAF T
VALVE (SLEEVE )
RIGHT CYLINDE R PASSAG E
POWE R CYLINDE R
Steering Gearbo xLOW SPEE D FEE D PASSAG E
The steerin g gearbo x i s th e rack-and-pinio n type . Th e valv e bod y uni t consist s o f th e valv e bod y unit , wher e th e flui d pas -
sag e i s regulate d b y th e flui d pressure , an d th e assis t contro l valv e uni t whic h regulate s th e flui d passag e t o th e rotar y
valv e accordin g t o vehicl e speed .
ASSIST CONTRO L VALV E UNI T
STEERIN G RAC K VALV
E BOD Y UNI T
ToRESERVOI R
From PUM P
POWE R CYLINDE RCYLINDE
R LINE S ASSIS
T CONTRO L VALV E UNI T
PUM P
To POWE R STEERIN G
SPEE D SENSO R
PUM
P OUTLE T
HIGH-PRESSUR E
HIGH SPEE D
FEE D PASSAG E
POWER STEERIN G
SPEE D SENSO R
RESERVOI R
LEFT CYLINDE R
PASSAG E
ProCarManuals.com

From pag e 17-1 2
Chec k forc e require d t o tur n th e
whee l (se e pag e 17-20 ).
Star t th e engin e an d measur e
force require d t o tur n th e whee lto th e righ t an d left . Differenc e o fth e forc e require d t o tur n th ewhee l t o th e righ t an d t o th e lef tshoul d b e 2. 9 N (0. 3 kgf , 0. 7 Ibf )
o r below . Abnorma
l
Check cylinde r pipe s A an d B fo r deformation .
Norma l No
t deforme d
Faulty valv e bod y uni t
Deforme d
Faulty cylinde r pip e
Measur e th e forc e require d t o
tur n th e whee l wit h th e powe r
steerin g spee d senso r hos e
plugge d an d th e vehicl e parke d(see pag e 17-20 ).
Abnorma l
Steering effor t belo w 2 4 N (2. 4 kgf , 5. 3 Ibf) . Connec t
th e senso r hos e a s it is .
I f th e steerin g effor t i s abov e 2 4 N (2. 4 kgf , 5. 3 Ibf) ,
replac e th e powe r steerin g spee d sensor .
Steerin g effor t abov e 2 4 N (2. 4 kgf , 5. 3 Ibf) . Chec k
th e assis t contro l valv e fo r stickin g o r a clogge d ori -
fice ; clea n th e valv e a s necessar y (se e pag e 17-55 ).
Assis t contro l valv e is norma l
Chec k th e gearbox .
Remov e th e gearbo x an d mea -
sur e th e pinio n torque .
Th e torqu e shoul d be ;
* 0. 6 - 1. 2 N- m (6 - 1 2 kgf-cm , 5. 2
- 1 0 Ibf-in ) wit h th e steerin g rac k
i n th e straigh t drivin g position .
* 1. 3 N- m (1 3 kgf-cm , 11. 3 Ibf-in )with th e steerin g rac k i n an y
othe r position .
Normal
Check th e part s othe r tha n th e gearbox-relate d part s fo r
prope r rotation .
• Imprope r rotatio n o f th e steerin g column-relate d part(s )
• Fault y steerin g join t
• Fault y rac k end/tie-ro d en d bal l joint s
• Interferenc e in th e steerin g syste m
Abnorma l
Adjus t th e rac k guid e (se e pag e
17-24 ), an d rechec k th e pinio n
torque.
Norma l Improperl y adjuste d rac k guid e
Abnorma l
Faulty gearbo x
ProCarManuals.com

Troubleshooting
General Troubleshootin g (cont'd )
Assist (excessivel y ligh t steering ) a thig h speed . Chec
k th e rac k guid e fo r prope r
adjustmen t (se e pag e 17-24 ).
Measur e forc e require d t o tur n
whee l wit h bypas s tub e join tinstalled , an d th e vehicl e parke d o n
dr y pave d surfac e (se e pag e 17-21 ). I
f th e proble m is no t correcte d b y
adjustin g th e rac k guide , adjus tthe fron t whee l alignmen t (se e
sectio n 18 ).
I f belo w th e specifications , chec k
th e powe r steerin g spee d sensor ,
assis t contro l valve , pressur e
contro l valv e an d valv e bod y uni t
fo r stickin g o r a clogge d orifice .
Shoc k o r vibratio n whe n whee l i s
turne d t o ful l lock . Chec
k th e rac k guid e fo r prope r
adjustmen t (se e pag e 17-24 ).
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
17-23 ).
Rac k guid e wa s backe d of f exces -sively.
Adjus t th e rac k guide .
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 .
Steering whee l wil l no t retur nsmoothly . Chec
k cylinde r line s A an d B fo r
deformation .
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 normal .
Remov e th e gearbo x fro m th e
fram e an d measur e th e pinio n
torqu e o n th e gearbox . A
o r B cylinde r lin e i s deformed ;
replac e it .
Whee l alignmen t i s abnormal ,
adjus t a s needed .
I t shoul d b e 0. 7 - 1. 2 N- m (7 -
1 2 kgf-cm , 6-1 0 Ibf-in ) o r les s
wit h th e steerin g rac k i n th e
straigh t ahea d drivin g position .
1. 3 N- m (1 3 kgf-cm , 11. 3 Ibf-in )
wit h th e steerin g rac k i n an y
othe r position .
I f th e measurement s ar e ou t o f
specifications , adjus t th e rac k
guide .
I f th e proble m is no t correcte d b y
adjustin g th e rac k guide , replac ethe gearbox .
ProCarManuals.com

Uneven o r roug h steering .
Improperly adjuste d rac k guide .
Bel t slippin g o n pulley .
Idl e spee d lo w o r erratic .
Ai r i n reservoir , o r chec k powe r
steerin g flui d level . Adjus
t rac k guid e (se e pag e 17-24 ).
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 17-23 ).
I f th e engin e stall s whe n th e whee l
i s turne d whil e vehicl e i s stoppe d
o r movin g a t lo w speed , adjus t idl e
speed (see section 11).
Check 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/ S
pum p housin g matin g surface s
an d th e pum p shaf t oi l sea l fo r
suctio n leaks . Replac e part s a s
necessary .
Steering whee l kick s bac k
durin g wid e turns . Pum
p bel t slippin g o n pulle y
(pum p stop s momentarily) .
Instal l 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 17-25 ).
Adjus t bel t tensio n (se e pag e
17-23 ) o r replac e belt .
Chec k if pum p pressur e is norma l
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 if 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 .
ProCarManuals.com

Pump Pressur e Chec k
Chec k th e flui d pressur e a s follow s t o determin e
whethe r 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 : Disconnec t th e hig h pressur e hos e wit h car e
s o a s no t t o spil l th e powe r steerin g flui d o n th e fram e
an d othe r parts .
1 . Disconnec t th e outle t hos e (high-pressure ) fro m th e
pum p outle t fitting , the n instal l th e P/ S join t adapte r
(pump) o n th e pum p outlet .
OUTLE T HOS E FITTIN G
(High-pressure )
P/ S PRESSUR E
GAUG E
07406-001000 1
HOSE ATTACHIN G BOL T
1 1 N- m (1. 1 kgf- m 8 Ibf-ft )
P/ S JOIN T ADAPTO R (HOSE )
07QAK-PV3012 0
PRESSURECONTROL VALV E
6 x 1. 0 m m BOL T
(Par t o f tool )
11 N- m(1.1 kgf-m , 8 Ibf-ft )
SHUT-OF F
VALVE
P/S JOIN T ADAPTO R (PUMP )
07QAK-PV3011 0
2. Connec t th e P/ S join t adapte r (hose ) t o th e powe r
steerin g pressur e gauge , the n connec t th e outle t
hos e (high-pressure ) t o th e adaptor .
3 . Instal l th e powe r steerin g pressur e gaug e t o th e P/ S
join t adapto r (pump) .
4 . Ope n th e shut-of f valv e fully .
5 . Ope n th e pressur e contro l valv e fully . 6
. Star t th e engine and le t i t idle .
7. Tur n th e steerin g whee l fro m lock-to-loc k severa l
times t o war m th e flui d t o operating temperature .
8 . Measur e steady-stat e flui d pressur e whil e idling . 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
uni t (se e Genera l Troubleshootin g 17-12 ).
9 . Clos e th e pressur e contro l valve , the n clos e th e
shut-of f valv e graduall y unti l th e pressur e gaug e
needl e is stable . Rea d th e pressure .
10 . 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 the 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 .
P/S PRESSUR E GAUG E07406-001000 1 PRESSUR ECONTROL VALV E
SHUT-OF F VALV E
ProCarManuals.com

Steering Gearbo x
Remova l
NOTE: Us e solven t an d a brus h t o was h of f an y oi l an d
dirt fro m th e valv e bod y unit , it s lines , an d th e en d o f
the gearbox . Blo w dr y wit h compresse d air .
1. Drai n th e powe r steerin g flui d a s describe d o n pag e
17-24 .
2. Rais e th e fron t o f vehicle , an d suppor t i t o n safet y
stands in th e prope r locations , (se e sectio n 1 )
3 . Remov e th e fron t wheels .
4 . Remov e th e driver' s airba g assembl y an d steerin g
whee l (se e pag e 17-27 ).
5 . Remov e th e steerin g join t lowe r bol t fro m th e
engin e compartment , an d mov e th e join t towar d
th e column .
STEERIN G JOIN T
6.
STEERIN G JOIN T
LOWE R BOL T
Remov e th e cotte r pi n fro m th e castl e nut , an d
remov e th e nut .
12 m m HE X NU T
7. Instal l th e 1 2 m m he x nu t o n th e bal l joint .
Be sur e tha t th e 1 2 m m he x nu t i s flus h wit h th e bal l
joint pi n end , o r th e threade d sectio n o f th e bal l
joint pi n migh t b e damage d b y th e specia l tool .
NOTE : Remov e th e bal l join t usin g th e Bal l Join t
Remover , 2 8 m m (07MA C-SL00200 ). Refe r t o pag e
18-12 for ho w to us e th e bal l join t remover .
8. Separat e th e tie-ro d bal l join t an d knuckl e usin g th e
specia l tool .
CAUTION : Avoi d damagin g th e bal l join t boot . 9
. Disconnec t th e tw o line s an d tw o hose s fro m th e
valv e bod y uni t o n th e steerin g gearbox .
CAUTION : Afte r disconnectin g th e hos e an d line ,
plug o r sea l th e hos e an d lin e wit h th e piec e o f tap e
or equivalen t t o preven t foreig n material s fro m
enterin g th e valv e bod y unit .
NOTE : I t i s no t necessar y t o loose n th e cylinde r
line s A an d B betwee n th e valv e bod y uni t an d th e
cylinder .
SENSOR RETUR N LIN ETo th e reservoi r
RETURN HOS E
To th e reservoi r
PUMP OUTLE T LIN E
Fro m th e pum p
VALV E BOD Y UNI T
10.
SENSO R INLE T HOS E
T o th e powe r steerin g spee d senso r
Remove th e splas h guard .
NOTE : Som e splas h guar d mountin g bolt s ar e als o
use d
as gearbo x mountin g bolts. The gearbo x will
til t
to th e sid e whe n thes e bolts are removed .
GEARBO X MOUNTIN G
BOLT S
SPLAS H GUAR D
SPLAS H GUAR D
MOUNTIN G BOLT S
BALL JOIN T REMOVER ,28 m m07MA C-SL0020 0
ProCarManuals.com