steering ACURA TL 1995 Service User Guide

Steering Gearbo x
Disassembl y (cont'd )
9. Remov e th e tw o flang e bolts , the n remov e th e valv e
body uni t fro m th e gearbo x (refe r t o th e '9 5 - 9 8
Acur a 2.5T L Servic e Manual , P/ N 61SW504) .
VALVE BOD Y UNI T
FLANGE BOL T
10. Dril l a 3 m m (0.1 2 in ) diamete r hol e approximatel y
2. 5 - 3. 0 m m (0.1 0 - 0.1 2 in ) i n dept h i n th e staked -
point o n th e cylinder .
NOTE:
• D o no t allo w meta l shaving s t o ente r th e cylinde r
housing .
• Afte r removin g th e cylinde r end , remov e an y
burr s a t th e stak e point .
STAKE D POIN T
CYLINDE R EN D
11. Instal l th e specia l too l t o th e steerin g gearbo x hous -
ing. Clam p th e too l i n a vis e wit h sof t jaw s a s
shown , the n loose n an d remov e th e cylinde r end .
CAUTION : D o no t clam p th e cylinde r housing .
PULLER YOKE :
(Commerciall y available )
Snap-On ® T/ N CJ123- 1
OTC® T/ N 737 2or equivalen t
STEERING GEARBO XHOUSING
STEERIN G RAC K
CYLINDE R EN D SEA L
REMOVE R ATTACHMEN T
07NA D-SR3020 A
CYLINDER EN D SEA L
Replace .
SHIMS
O-RIN G
Replace . CYLINDE
R EN D
Chec k th e rubbe r sto p i n th e cylinde r en d fo r
damag e o r deterioration . I f th e rubbe r sto p isdamaged , replac e th e cylinde r end .
Depth : 2. 5 - 3. 0 m m(0.1 0 - 0.12 in)
12. Se t th e steerin g gearbo x i n a pressbo x s o th e
gearbo x housin g point s upward .
13. Inser t a 6" long , 3/8 " driv e extensio n int o th e spe -
cial tool .
14. Pres s th e cylinde r en d sea l an d steerin g rac k ou t o f
th e gearbox .
NOTE : Hol d th e steerin g rac k t o kee p it fro m fallin g
whe n presse d clear .
CAUTION : B e carefu l no t t o damag e t o inne r sur -
fac e o f th e cylinde r housin g wit h th e tool .
Pres s
STEERIN G GEARBO X
6
" LON G 3/8 " DRIV E EXTENSION :
(Commerciall y available )
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Steering Gearbo x
Disassembl y (cont'd )
19. Chec k th e rubbe r sto p fo r damag e o r deterioratio n if
OK , g o o n ste p 20 ; i f not , replac e th e rubbe r stop ,
ste p a s show n below :
Remov e th e rubbe r sto p b y pryin g it ou t o f th e gear -
bo x housin g wit h a fla t ti p screwdriver .
CAUTION: Protec t th e pr y poin t o n th e gearbo x
housing wit h sho p towel .
FLAT TI P SCREWDRIVE R
GEARBOX HOUSIN G
Shop towe l
RUBBE R STO P
Replace .
20. Carefull y pr y th e pisto n sea l rin g an d O-rin g of f th e
rac k piston .
CAUTION : B e carefu l no t t o damag e th e insid e o f
sea l rin g groov e an d pisto n edge s whe n removin g
th e sea l ring .
O-RIN GReplace .
PISTON SEA L RIN GReplace .
RUBBE
R STO P
Cut-ou t
Cut-ou t
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Reassembly

NOTE:

• Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-

vent.

• Always replace the O-rings and rubber seals with new ones before assembly.

• Apply the recommended power steering fluid to the parts indicated in the assembly procedures.

• Do not allow dust, dirt, or other foreign materials to enter the power steering system.

• Use the appropriate special tools where necessary.

FLANGE BOLT

9 N-m (0.9 kgf-m, 6.5 Ibf-ft)
FLANGE BOLT

20 N-m (2.0 kgf-m, 14 Ibf-ft)

CAP
PINION DUST COVER

VALVE HOUSING

26 N-m (2.7 kgf-m, 20 Ibf-ft)

CYLINDER LINE A

VALVE OIL SEAL

Replace.

SHIMS

CYLINDER END

78 N-m (8.0 kgf-m, 58 Ibf-ft)

CYLINDER END SEAL

Replace.
BACKUP RING

Replace.
CAP SEAL

Replace.

PRESSURE CONTROL

VALVE
SPRING

HOUSING SEAL

Replace.

CYLINDER LINE B
VALVE BODY
ASSIST CONTROL

VALVE

VALVE SEAL RING

Replace.

ROLLER BEARING

Replace.

O-RING

Replace.

SLEEVE SEAL

RINGS

Replace.
CIRCLIP

Replace.

SLEEVE
20 N-m (2.0 kgf-m, 14 Ibf-ft)

BACKUP RING

PINION SHAFT
LOCKNUT

RACK GUIDE SCREW

O-RING

Replace.
SPRING
RACK GUIDE

STEERING RACK
CYLINDER END SEAL

Replace.
PISTON SEAL RING

Replace.
CYLINDER HOUSING

GEARBOX HOUSING
O-RING

Replace.
RUBBER STOP

Check for damage or

deterioration.
VALVE SEAL RING

Replace.
O-RING

Replace.ProCarManuals.com

Steering Gearbo x
Reassembl y (cont'd )
Steering Rac k Installatio n
1. I f remove d th e rubbe r stop ; positio n th e ne w rub -
be r sto p i n th e gearbo x housing , the n pres s i t i n
usin g a hydrauli c pres s an d th e specia l tool s a s
shown .
NOTE : Mak e sur e tha t th e specia l too l presse s
agains t th e meta l portio n o f th e rubbe r stop .
Press
META L RIN G
DRIVE R07749 - 0010000
ATTACHMENT ,32 x 35 m m
RUBBE R STO P
Replace .
GEARBO X HOUSIN G
2. Coa t th e pisto n sea l rin g guid e wit h powe r steerin g
fluid , an d slid e it ont o th e rack , bi g en d first .
3 . Positio n th e ne w O-rin g an d ne w pisto n sea l rin g o n
th e specia l tool , the n slid e the m dow n towar d th e
big en d o f th e tool .
NOTE :
• D o no t ove r expan d th e resi n sea l rings . Instal l
th e resi n sea l ring s wit h car e s o a s no t t o dam -
ag e them . Afte r installation , b e sur e t o contrac t
th e sea l rin g usin g th e specia l too l (sizin g tool) .
• Replac e piston' s O-rin g an d sea l rin g a s a set .
4 . Pul l th e O-rin g of f int o th e pisto n groove , the n pul l
th e pisto n sea l rin g of f int o th e pisto n groov e o n to p
o f th e O-ring .
PISTON
PISTON SEA L RIN GGUID E07LAG-SM4010 0 o r07LA G-SM4010 A
5. Coa t th e pisto n sea l rin g an d th e insid e o f th e spe -
cia l too l wit h powe r steerin g fluid .
6 . Carefull y slid e th e too l ont o th e rac k an d ove r th e
pisto n sea l ring .
7 . Mov e th e specia l too l bac k an d fort h severa l time s
t o mak e th e pisto n sea l rin g fi t snugl y in th e piston .
PISTON SEA L RIN GReplace .
PISTON SEA L RIN GSIZIN G TOO L07LA G-SM4020 0 o r07LA G-SM4020 A
8. Wra p viny l tap e aroun d th e rac k teet h an d rac k en d
edges , an d coa t th e surfac e o f th e tap e wit h th e
powe r steerin g fluid .
NOTE : Mak e sur e tha t th e viny l tap e is wrappe d care -
full y s o tha t ther e is n o steppe d portion .
VINYL TAP E
O-RIN GReplac ePISTON SEA L RIN GReplace .
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Steering Gearbox

Reassembly (cont'd)

CYLINDER END SEAL

Replace.

VINYL TAPE

19. Remove the vinyl tape from the steering rack, then

push in the cylinder end seal with your finger.

NOTE:

• Remove any residue of tape adhesive.

• Take care not to damage the cylinder end seal

with the threads and burrs at the staked position

of the gearbox.

20. Install special to the steering gearbox, then clamp

the tool in a vise with soft jaws as shown.

CAUTION: Do not clamp the cylinder housing.

PULLER YOKE:

(Commercially available)

Snap-On® T/N CJ123-1

OTC® T/N 7372

or equivalent
21. Coat the inside surface of the cylinder end with

power steering fluid, then install the cylinder end by

screwing it into the cylinder housing.

22. Remove the puller yoke from the steering gearbox.

23. After tightening the cylinder end, stake the point of

the cylinder housing shown below.

NOTE: Stake the cylinder in the position opposite

from where the stake was removed during disas-

sembly.

CYLINDER END

CYLINDER END

78 N-m (8.0 kgf-m, 58 Ibf-ft)
BUSHING

Be careful not to damage

the bushing when inserting

the cylinder end.
Grooved side.,
Stake point. Depth: 1.0 mm (0.04 in)

CYLINDER HOUSING

4.0 mm
(0.16
in)

STEERING GEARBOX
16. Wrap vinyl tape around the rack end edges, and

coat the surface of the tape with the power steering

fluid.

NOTE: Make sure that the vinyl tape is wrapped care-

fully so that there is no stepped portion.

17. Coat the inside surface of the new cylinder end seal

with power steering fluid.

18. Install the cylinder end seal onto the steering rack

with its grooved side toward the piston.

CAUTION: When installing the cylinder end seal,

be careful not to damage the sealing lip face of the

seal with the edges of the steering rack.

Staked position.

Make sure the spring

is in the cylinder end seal.,ProCarManuals.com

Steering Gearbo x
Reassembl y (cont'd )
30. Instal l cylinde r line s A an d B .
NOTE :
• Clea n th e joint s o f cylinde r line s A an d B
thoroughly . Th e joint s mus t b e fre e o f foreig n
material .
• Instal l cylinde r line s A an d B by lightin g th e flar e
nut s b y han d first , the n tighte n th e flar e nut s t o
th e specifie d torque .
CYLINDE R LIN E B
CYLINDE R LIN E A
2 0 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
2 6 N- m (2. 7 kgf-m , 2 0 Ibf-ft )
31. Greas e th e slidin g surfac e o f th e rac k guide , an d
instal l i t ont o th e gearbo x housing .
32 . Appl y a thi n coa t o f greas e t o th e ne w O-ring , an d
instal l i t o n th e rac k guid e screw .
33 . Instal l th e spring , rac k guid e scre w an d locknu t o n
th e gearbo x housing .
34 . Adjus t th e rac k guid e scre w (se e pag e 17-5 ).
NOTE : Afte r adjusting , chec k tha t th e rac k move s
smoothl y b y slidin g th e rac k righ t an d left .
RAC K GUID ESCRE W
LOCKNU T
35. Instal l th e ne w loc k washe r i n th e groov e i n th e
steerin g rack .
Cente r lin e o f th eflat section .Roll Pi n Drift , (Snap-o n No . PPR 8
o r equivalent ) COMMERCIALL Y
AVAILABLE
LOCK WASHE R
STEERIN G RAC K
WOOD BLOC K
SLO
T
TUB
36. Scre w eac h rac k en d int o th e rack .
37 . Hol d th e steerin g rac k wit h a wrench , an d tighte n
th e rac k en d wit h another .
CAUTION : B e carefu l no t t o damag e th e rac k sur -
fac e wit h th e wrench .
38 . Afte r tightenin g th e rack , end , stak e th e fou r sectio n
o f loc k washe r wit h th e too l an d a hydrauli c press .
NOTE:
• Plac e th e woo d bloc k o n th e pres s table , the n se t
th e loc k washe r sectio n o f th e rac k en d o n th e
woo d bloc k securely .
• B e sur e th e too l i s aligne d wit h th e fla t section s
o f th e steerin g rac k en d befor e pressing .
• Stak e th e loc k washe r i n th e cente r o f th e fla t
sectio n o f th e steerin g rac k end .
STEERIN G RAC K EN D64 N- m(6.5 kgf-m , 4 7 Ibf-ft )
LOC
K WASHE RReplace.
STAKE POIN T
Flat sectio n o f th e
steerin g rac k end .
Pres s
SPRIN GRAC
K GUID E
O-RIN
G
Replace .
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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

Steering Gearbo x
Installatio n (cont'd )
13. Reconnec t th e tie-ro d end s t o th e steerin g knuckles ,
tighte n th e castl e nu t t o th e specifie d torque , an d
instal l ne w cotte r pins .
NOTE : Befor e connectin g th e tie-ro d ends , chec k
th e bal l join t pi n tapere d sectio n an d thread s sec -
tio n fo r greas e contamination , an d wip e i t i f neces -
sary.
CAUTION : Torqu e th e castl e nu t t o th e lowe r
torqu e specification , the n tighte n it onl y fa r enoug h
t o alig n th e slo t wit h th e pi n hole . D o no t alig n th e
nu t b y loosening .
14 . Instal l th e fron t wheels .
15 . Fil l th e syste m wit h powe r steerin g fluid , an d blee d
ai r fro m th e syste m (refe r t o th e '9 5 - 9 8 Acur a
2.5T L Servic e Manual , P/ N 61SW504) .
16 . Afte r installation , perfor m th e followin g checks .
• Star t th e engine , allo w it t o idle , an d tur n th e
steerin g whee l fro m lock-to-loc k severa l time s t o
war m u p th e fluid . Chec k th e gearbo x fo r leaks .
• Adjus t th e fron t to e (se e sectio n 18 ).
• Chec k th e steerin g whee l spok e angle . Adjus t b y
turning the righ t an d lef t tie-rods , i f necessary .
NOTE : Tur n th e righ t an d lef t tie-rod s equally .
CASTLE NU T49 - 5 9 N- m(5. 0 - 6. 0 kgf-m , 3 6 - 4 3 Ibf-ft )
COTTE R PI NReplace .On reassembly , ben d
th e cotte r pi n a s shown .
ProCarManuals.com

Steering Gearbo x
Ball Join t Boo t Replacemen t
'95 - 9 7 models :
1 . Remov e th e boo t se t rin g an d th e boot .
CAUTION : D o no t contaminat e th e boo t installa -
tio n sectio n wit h grease .
2 . Pac k th e interio r o f th e boo t an d li p wit h grease .
3 . Wip e th e greas e of f th e slidin g surfac e o f th e bal l
pin , the n pac k th e lowe r are a wit h fres h grease .
CAUTION :
• Kee p greas e of f th e boo t installatio n sectio n an d
th e tapere d sectio n o f th e bal l pin .
• D o no t allo w dust , dirt , o r othe r foreig n materi -
al s to ente r th e boot .
BALL PI N TAPERE DSECTIONWipe of f th e greas e
BOOT INSTALLATIO NSECTIONWipe of f th e grease .
BOOT INSTALLATIO NSECTIONWipe of f th e grease .
4. Instal l th e boo t i n th e groov e o f th e boo t installatio n
sectio n securely , the n blee d air .
ADJUSTIN G BOL TAdjus t th e dept hby turnin g th e bolt .
BAL L JOIN T BOO TCLIP GUID E07974-SA5070 0
BOOTSET RIN G
5. Adjus t th e specia l too l wit h th e adjustin g bol t unti l
the en d o f th e too l align s wit h th e groov e o n th e
boot .
Slide th e se t rin g ove r th e too l an d int o positio n .
CAUTION : Afte r installin g th e boot , chec k th e bal l
pi n tapere d sectio n fo r greas e contaminatio n an d
wip e it i f necessary .
LIP
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Front Suspensio n
Knuckle/Hu b Replacemen t (cont'd )
8. Remov e th e 6 m m brak e dis c retainin g screws .
9 . Scre w tw o 8 x 1 2 m m bolt s int o th e dis c t o pus h i t
awa y fro m th e hub .
NOTE : Tur n eac h bol t tw o turn s a t a tim e to preven t
cockin g th e dis c excessively .
9.8 N- m(1.0 kgf-m , 7 Ibf-ft )
8 x 1 2 m mBOL T
CAUTION : B e carefu l no t t o damag e th e bal l join t boot .
10 . Clea n an y dir t o r greas e of f th e bal l joint .
11 . Remov e th e cotte r pi n fro m th e bal l join t castl e nut ,
an d remov e th e nut .
12 . Instal l a 12 m m he x nu t o n th e bal l joint . B e sur e tha t
the 1 2 m m he x nu t i s flus h wit h th e bal l join t pi n en d
to preven t damag e t o th e threade d en d o f th e bal l
joint.
13. Appl y greas e t o th e specia l too l o n th e area s
shown . Thi s wil l eas e installatio n o f th e too l an d
preven t damag e t o th e pressur e bol t threads .
Apply greas e here .
14. Instal l th e specia l too l a s shown . Inser t th e jaw s
carefully , makin g sur e yo u d o no t damag e th e bal l
join t boot . Adjus t th e ja w spacin g b y turnin g th e
pressur e bolt .
NOTE : I f necessary , appl y penetratin g typ e lubrican t
t o loose n th e bal l joint .
CASTL E NU T49 - 5 9 N- m(5. 0 - 6. 0 kgf-m , 36-4 3 Ibf-ft )
HEX NU T
COTTE RPINReplace .On reassembly ,
ben d th e cotte r pi n a s shown .
15. Onc e th e too l i s i n place , tur n th e adjustin g bol t a s
necessar y t o mak e th e jaw s parallel . The n hand -
tighte n th e pressur e bolt , an d rechec k th e jaw s t o
mak e sur e the y ar e stil l parallel .
PRESSUR E BOL T
NOTE : Afte r makin g th e adjustmen t t o th e adjustin g
bolt , b e sur e th e hea d o f th e adjustin g bol t i s i n thi s
positio n t o th e allo w th e ja w to pivot .
16 . Wit h a wrench , tighte n th e pressur e bol t unti l th e
bal l join t shaf t pop s loos e fro m th e steerin g arm .
Wea r ey e protection . Th e bal l join t ca n
brea k loos e suddenl y an d scatte r dir t o r othe r debri s
in you r eyes .
17. Remov e th e tool , the n remov e th e nu t fro m th e en d
of th e bal l joint , an d pul l th e bal l join t ou t o f th e
steering/suspensio n arm . Inspec t th e bal l join t boot ,
an d replac e it i f damaged .
- ADJUSTIN G BOL T
BAL
L JOIN T
REMOVER , 2 8 m m
07MA C-SL0020 0
BRAKE DIS C
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