ACURA RL KA9 1996 Service Repair Manual

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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5. Remove the boot bands and tie-rod clips. Pull the

boots away from the ends of the gearbox.

6. Hold the steering rack with one wrench ('99 - 01

models: left end only), and unscrew the rack end with

another wrench.

NOTE: '96 - 98 models shown.

CAUTION: Be careful not to damage the rack sur-

face with the wrench.
7. Loosen the locknut, then remove the rack guide

screw and O-ring ('96 - 98 models only).

8. Remove the spring and rack guide from the gearbox

housing.

9. Remove cylinder lines A and B from the gearbox.

10. Drain the fluid from the cylinder fittings by slowly

moving the steering rack back and forth.ProCarManuals.com

Disassembly (cont'd )
11. 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 (se e pag e 17-3 6 fo r valv e
body uni t disassembly) . 13
. Instal l th e specia l too l o n th e gearbo x housing .
CAUTION : D o no t clam p th e cylinde r housing .
Power Steerin g Gearbo x
12. 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 -
poin t o n th e cylinder .
NOTE:
• D o no t allo w meta l shaving s t o ente r th e cylinder .
• Afte r removin g th e cylinde r end , remov e an y
burr s a t th e stak e point . 14
. 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 .
15 . Remov e th e gearbo x housin g fro m th e vise , an d se t
i t i n a pres s s o th e gearbo x point s upward .
16 . Inser t a 6 " long , 3/8 " driv e extensio n int o th e spe -
cia l tool .
17. Pres s th e cylinde r en d sea l an d steerin g rac k ou t o f
the gearbo x housing .
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 wal l wit h th e tool .
CYLINDE R EN D SEA L
REMOVE R ATTACHMEN T
07NA D-SR3020 A
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18. Remov e th e cylinde r en d sea l fro m th e steerin g
rack.
20. Inser t a 24 " lon g 3/8 " driv e extensio n int o th e cylin -
de r an d th e specia l too l fro m th e gearbo x side .
CAUTION : B e carefu l no t t o damag e th e insid e sur -
fac e o f th e cylinde r wal l wit h th e tools .
21 . Se t th e gearbo x housin g i n a press , the n pres s ou t
th e cylinde r en d sea l an d backu p rin g fro m th e
gearbo x housing .
CAUTION :
• Kee p th e too l straigh t t o avoi d damagin g th e
cylinde r wall . Chec k th e too l angle , an d correc t i t
i f necessary , whe n removin g th e cylinde r en d
seal .
• Us e a pres s t o remov e th e cylinde r en d seal . D o
no t tr y t o remov e th e sea l b y strikin g th e tool . I t
wil l brea k th e backu p ring , an d th e cylinde r en d
sea l wil l remai n in th e gearbo x housing .
19 . Tur n th e specia l too l s o i t wil l fi t throug h th e en d o f
th e gearbo x housing , the n positio n specia l too l o n
th e backu p rin g a s show n below .
NOTE : Mak e sur e tha t th e specia l too l i s securel y
positione d o n th e backu p rin g edges .
CYLINDE R EN D
SEA L REMOVE R
ATTACHMEN T
07TAF-SZ5010 0
CYLINDER EN D SEA L
REMOVE R ATTACHMEN T
07TAF-SZ5010 0
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Disassembly (cont'd )
22. Chec k th e rubbe r sto p fo r damag e o r deterioration ;
i f OK , g o o n ste p 23 ; i f not , replac e th e rubbe r sto p
as show n below :
Remov e th e rubbe r sto p b y pryin g i t ou t o f th e gear -
box 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
housin g wit h sho p towel .
Valve Bod y Uni t Disassembl y
Valve bod y unit :
24 . Remov e th e pinio n dus t cover .
Power Steerin g Gearbo x
25. Befor e removin g th e valv e housing , appl y viny l tap e
t o spline s o f th e pinio n shaft .
26 . Separat e th e valv e housin g fro m th e pinio n shaft /
valv e usin g a press .
23 . 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 .
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27. Chec k th e inne r wal l o f th e valv e housin g wher e th e
sea l rin g slide s wit h you r finger . I f ther e i s a ste p i n
th e wall , th e valv e housin g i s worn . Replac e th e
valv e housing .
NOTE:
• Ther e ma y b e th e slidin g mark s fro m th e sea l
rin g o n th e wal l of the valv e housing . Replac e
th e valv e housin g onl y i f th e wal l i s stepped .
• '9 6 - 9 8 mode l only ; whe n th e valv e housin g i s
replaced , instal l ne w 4 4 m m shim(s ) o n th e bear -
in g surfac e o f th e housin g t o adjus t th e thick -
ness.
29. Remov e th e sna p rin g an d pinio n shaf t sleev e fro m
th e pinio n shaft .
30 . Usin g a cutte r o r a n equivalen t tool , cu t an d remov e
th e fiv e sea l ring s fro m th e sleeve .
CAUTION : B e carefu l no t t o damag e th e edge s o f
th e sleev e groove s an d oute r surfac e whe n remov -
in g th e sea l rings .
28 . Chec k fo r wear , burr s an d othe r damag e t o th e
edge s o f th e groove s in th e sleeve .
NOTE : Th e pinio n shaf t an d sleev e ar e a precisio n
matche d set . I f eithe r th e pinio n shaf t o r sleev e
mus t b e replaced , replac e bot h part s a s a set .
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Power Steerin g Gearbo x
Disassembl y (cont'd )
31. Usin g a cutte r o r a n equivalen t tool , cu t th e valv e
sea l rin g an d O-rin g a t th e groov e th e pinio n shaft .
Remov e th e valv e sea l rin g an d O-ring .
CAUTION : B e carefu l no t t o damag e th e edge s o f
th e pinio n shaf t groov e an d oute r surfac e whe n
removin g th e valv e sea l rin g an d O-ring . 33
. Pres s th e valv e oi l sea l an d rolle r bearin g ou t o f th e
valv e housin g usin g a hydrauli c pres s an d th e spe -
cia l too l show n below .
PILOT COLLA R
07GA F-PH7010 0
32. Remov e th e valv e oi l sea l an d backu p rin g ('9 6 - 9 8
models ) o r wav e washe r ('9 9 - 0 1 models ) fro m th e
pinio n shaft .
NOTE:
• Inspec t th e bal l bearin g b y rotatin g th e oute r
rac e slowly . I f ther e i s an y excessiv e play , re -
plac e th e pinio n shaf t an d sleev e a s a n assem -
bly.
• Th e pinio n shaf t an d sleev e ar e a precis e fit ; d o no t
intermi x ol d an d ne w pinio n shaft s an d sleeves . Assis
t contro l valv e unit :
34 . Remov e th e ca p fro m th e valv e body .
35 . Remov e th e ca p sea l fro m th e cap .
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37. Check the two control valves.

NOTE: If the valves are damaged, replace the steer-

ing gearbox as an assembly.

Assist Control Valve:

• Inspect its surface for scoring and scratches.

• Slip it back into the valve body unit, and make

sure it slides smoothly without drag or side play.
38. Separate the valve body and valve housing.

39. Remove the housing seal and dowel pins from the

valve body unit.
Pressure Control Valve:

• Inspect its surface for scoring and scratches.

• Slip it back into the valve body unit, and make

sure it slides smoothly without drag or side play.
36. Remove the pressure control valve, assist control

valve and springs from the valve body.ProCarManuals.com

Reassembly
NOTE:
• Clea n th e disassemble d part s wit h a solvent , an d dr y the m wit h compresse d air . D o no t di p th e rubbe r part s i n a sol -
vent .
• Alway s replac e th e O-ring s an d rubbe r seal s wit h ne w one s befor e assembly .
• Appl y th e recommende d powe r steerin g flui d t o th e part s indicate d in th e assembl y procedures .
• D o no t allo w dust , dirt , o r othe r foreig n material s t o ente r th e powe r steerin g system .
• Us e th e appropriat e specia l tool s wher e necessary .
Power Steerin g Gearbo x
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2. Instal l th e valv e springs .
3 . Coa t th e pressur e contro l valv e an d assis t contro l
valv e wit h powe r steerin g fluid , the n instal l the m
int o th e valv e body .ATTACHMENT ,32 x 35 m m07746-001010 0DRIVER07749-001000 0
Valve bod y unit :
6 . Appl y powe r steerin g flui d t o th e sea l rin g li p o f th e
valv e oi l seal , the n instal l th e sea l i n th e valv e hous -
in g usin g a hydrauli c pres s an d th e specia l tool s a s
shown .
CAUTION : Instal l th e valv e oi l sea l wit h it s groove d
sid e facin g th e tool .
4
. Coa t th e ca p sea l wit h powe r steerin g fluid , an d
instal l th e it i n th e groov e o f th e cap .
5 . Instal l th e cap on th e valv e body .
Valve Bod y Uni t Reassembl y
Assist contro l valv e unit :
1. Coa t th e housin g sea l wit h powe r steerin g fluid , an d
instal l i t i n th e groov e o f th e valv e housing .
The n instal l th e valv e body .
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