Face HONDA CIVIC 1997 6.G Workshop Manual

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t5.
16.
14. Assemble a 12 x 1.25 mm flange nut onto a 12 x 175
mm grade 10 flange bolt as shown.
NOTE: Wrap the tlange portion of the bolt with
vinyl tape to protect the cylinder.
12,mm FLANGE
BOLT12 mm FLANGE NUTVINYL TAPG {p/N 90i77 - SLo - 000}
Install the flange bolt into the end of the steering
rack until it bottoms in the hole, then back the
flange bolt out 'll4 turn. Hold the flange bolt, and
tighten the flange nut against the rack by hand.
Install the bearing separator on the gearbox housing
a5 snown.
FLANGE BOLT
BEARING SEPARATOR0 - 1112" I
lCommercially availablo)
STEERING RACK
CYLINDER END SEAL
Set the gearbox in a press so the gear housing point
upward, then press the cylinder end seal and steer-
ing rack out of the gearbox
NOTE: Hold the steering rack to keep it from falling
when pressed clear.
CAUTION:
. Be carsful not damage to inn6l surface ot the
cylinder housing with the flange bolt.
. Do not place your lingers under th€ ste€ring
rack.
t./
17.
12 x 175 mm Ptess
1.,
the spe-
srcle.
securely
Replace. J__--'- ,----)t'| ,-----'" ,-,-'-'| fiN ----'
| .Wl'----
I
t
-'4a
| ^--.'--4
A ooY----- \
Q) * srerhtnc nact
20. lnsert a 24" long,3E" drive extension and
cial tool into the cylinder from the gearbox
NOTE: Make sure that the special tool is
positioned on the backup ring edges'
18, Remove the 12 mm bolt and nut from the steering
rack,
19. Remove the cylinder end seal from the steering
racK.
CYLINDER HOUSING
CAUTION: Be caroful not damago to inner surfaco
of the cylinder housing with the specisl tool'
21. Set the gearbox in a press, then press out the cYlin-
der end seal and backup ring from the gearbox,
GAUTION:
. Keep the tool sttaight to avoid damaging the cylin'
der wall. Check th€ tool angls, and corr€st it if nec-
€ssary, whon rsmoving the cylinder snd seal.
. Uss a pross to removs tho cylinder end seal. Do
not try to removo ths seal by striking the tool h
will br€ak the backup ring. and the cylinder snd
s€al will lemain in tho gearbox.
BACKUP RING
CYLINDER END SEAL
CYLINDER END SEALREMOVER ATTACHMENT07NAD - SR3020A
(cont'd)
17-51
Pross

Steering Gearbox
Disassembly (cont'dl
22. Carelully pry the piston seal ring and O-ring off theprslon rack.
CAUTION| Be caletul not to damage the inside ofseal ring groove and piston edges when removing
the seal rin9,
Replace.
17-52
Valve Body Unii Disassembly
23. Eefore removing the valve housing, apply vinyl tapeto splines of the pinion shaft.
24. Separate the valve housing from the pinion shaft/
valve using a press.
VALVE HOUSING
Vinylt.pe
PINION SHAFT
Check the inner wall of the valve housing where theseal ring slides with your finger. lf there is a step inthe wall, the valve housing is worn. Replace thevalve housing.
NOTE:
There may be the sliding marks from the sealring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.When the valve housing is replaced, jnstall new
shim(s) on the bearing surface of the housing toadjust the thickness.
Check the inside of valve housingwhether the wall is stepped.

I
l./
26. Check for wear. burrs and other damage to the
edges of the grooves in the sleeve'
NOTE: The pinion shaft and sleeve are a precision
matched set lf either the pinion shaft or sleeve
must be replaced, replace both parts as a set'
SLEEVE SEAL RINGS
Check for Peel off or
damage.
27. Remove the circliP and Pi
pinion shaft.
nion shaft sleeve from the
1.,
-r t rt . 28. Using a cutter or an equivalent tool, cut and remove
the lour seal rings from the sleeve'
CAUTION: Be careful not to damage the edges of
the slgevs grooves and outer surface whsn lemov-
ing the seal rings.
29.Using a cutter or an equivalent tool, cut the valve
seal iing and O-ring at the groove the pinion shaft'
Remove the valve seal ring and O-ring'
CAUTION: Be careful not to damage the edges oI
the pinion shaft gloove and outer surface when
removing the valve seal ling and O-ring'
VALVE SEAL RING
Replace.
(cont'd)
SLEEVE
Cutting slot Posrtlon.

Steering Gearbox
Reassembly (cont'd)
Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl taoe with
the power steering fluid.
2. Install the backup ring ('96 -'97 models) or wavewasher ('98 -'00 models) with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil sealwith power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being
careful not to damage the sealing lip.
Vinyl t.po{Stepped ponion}
Tap6red position.
BACKUPGroove side.
sure the spring isseatod in the oil seal.
'98 - '00 mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Apply vinyl tape to the splines and stepped portion
of the shaft, and coat the surface of the vinyl tapewith the power steering fluid.
Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaft
and the groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft,
'96 - '97 models:
lip
7.
VALVE SEAL RIiIGReplace.Do not over-expand.
17-56
8. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
9. Apply power steering fluid to the inside of the spe-cial tool. Set the larger diameter end of the specialtool over the valve seal ring.
10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.11, Remove the soecial tool.
12. Turn the special tool over, and set the smaller diam-eter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinion
shaft.
PISTON SEAL BINGSIZING TOOL07NAG - SR:togoAol07NAG - SR3|X)00
(g(m
Use the larger diameterend of the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe specialtool.

I
14.
Apply power steering fluid to the surface of the spe-
cial tool. Set the new seal rings over the special tool
from the smaller diameter end of the tool, and
expand the seal rings. Do two rings at a time from
each end of the sleeve.
NOTE;
. Do not over-expand the seal ring. Installthe resin
seal rings with care so as not to damage them'
After installation, be sure to contract the seal
rings using the specialtool (sizing tool).
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleeve seal rings as they are not compatible
Set the special tool in the grooves in the sleeve, and
set each ring in each groove securely.
NOTE: After installation, compress the seal rings
with your fingers temPorarilY
BALL JOINT BOOI CLIP GUIDE
07S7,1- SA50800
SLEEVE
15. Apply power steering fluid to the seal rings on the
sleeve, and to the entire inside surface of the spe-
cial tool.
16. lnsert the sleeve into the specialtool slowly'
17. Move the sleeve each direction several times to
make the seal rings snugly fit in the sleeve'
NOTE: Be surerings are not turned uP.
SITEVE SEAL RINGSIZING TOOL0797a - SA5020A or07974 - SA50200
that the seal
fr
J
17-57
18. Apply power steering fluid to the surface o{ the pin-
ion shaft. Assemble the sleeve over the pinion shaft
by aligning the locating pin on the inside of the
sleeve with the cutout in the shaft. Then install the
new circlip securely in the pinion shaft groove'
NOTE:
Be careful not to damage the valve seal ring
when inserting the sleeve.
Installthe circlip with its radiused side toward the
sleeve.
Apply power steering fluid to the seal ring lip of the
valve oil seal. then install the seal in the valve hous-
ing using a hydraulic press and special tools as
shown.
CAUTION: Install the valve oil seal with its grooved
side facing the tool.
'19.
ATTACHMENT.32x35mm0774.6 - q)101(x)Pre3s
IDRIVER07749 - 0010000
VALVE OIL SEALReplace.Make sure thespring is in the
oil seal. (cont'd)

Steering Gearbox
Reassembly (cont'd)
SLEEVE SEAL RINGSReplace.8e sure that theseal nngs are notturned up, theninsta ll.
21. Apply vinyl tape to the pinion shaft. then coat thevinyltape with power steering fluid.
Sealing lip face.VALVE OIL SEAL
VALVE HOUSING
Press the new bearing ('96 - '97 models) or newbushing ('98 -'00 models) into the valve housingusing a hydraulic press and special tool as shown,
NOTE: Place the roller bearing ('96 -'97 models) onthe valve housing with the stamped letter facing uptowards the valve side.
DRIVER077itg-001tXlOO
22. Insert the pinion shaft into the valve housino.
CAUTION: Be careful noi to damage th€ valve sealrings.
23. Remove the vinyltape from the pinion shaft.
20.
Pr033
+3:Ix35mm07746 - 0010,t(x)
'96 - '97 models:ROLLER BEARINGLetter stamped taceupward.
ATTACHMENT,
'98 - '00 modob:
?/_vusHrNG
['---v-lt
\4)
PINION
E
17-5A
24. Press the pinion shaft/sleeve using a hydraulicpress as shown.
NOTE: Check that the pinion shafvsleeve turnssmoothly by turning the pinion shaft.

)
Steering Rack Reassembly
25. Coat the piston seal ring guide with power steering
fluid, then slide it onto the rack, big end first'
26. Position the new O-ring and new piston seal rlng on
the special tool, then slide them down toward the
big end of the tool
NOTE:
. Do not over expand the resin seal rings lnstali
the resin ;eal rings with care so as not to dam-
age them. After installation, be sure to contract
the seal ring using the specialtool (sizing tool)
. Replace the piston's O-ring and seal ring as a set'
27. Pull the O-ring off into the piston groove, then pull
the piston seal ring off into the piston groove on top
ol the O-ring
PISTON SEAL RINGGUIDE07GAG - SD4O10A ol
07GAG - SD,ol(xt
Coat the piston seal ring and the inside of the spe-
cial toolwith power steering fluid.
Carefully slide the tool onto the rack and over the
piston seal ring.
Move the special tool back and forth several times
to make the piston seal ring fit snugly in the piston'
PISTONReplace.
E
PISTON
31. Wrap vinyl tape around the rack teeth and rack end
edges, then coat the surface of the tape with the
power steering fluid
NOTE: Make sure that the vinyl tape is wrapped
carefully so that there is no stepped portion
Coat the inside surface of the new cylinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston.
CAUTION: When installing the cylinder end seal,
be caieful not damage the sealing lip face of tho
seal with the edgss or teeth of th€ ste€ring rack'
CYLINDER END SEAL
Make sure thesPring is in the cylinder
end soal
Remove the vinyl tape from the steering rack
NOTE: Remove any residue oftape adhesive(cont'dl
17-59

Steering Gearbox
Reassembly {cont'd)
35. Install the new backup ring on the steering rack,then place the cylinder end seal to piston.
Grease the steering rack teeth, then Insen the steer-ing .ack into the gear housing.
CAUTION: Be careful not to damage to inner sur-face of the cylindsr housing with the rack edges.
36.
BACKUP RING
17-60
37. Install the flange bolt into the end of the steerinorack until it bottoms in the hole, then back thlflange bolt out 1/4 turn. Hold the flange bolt andtighten the flange nut against the rack by hand.
38. Install the cylinder end seal into the bottom of thecylinder by pressing on the bolt with a press asshown.
CAUTION: Do not push on the boh with excessiveforce as it may damage tho cylinder end seal.
12 x 175 mm FLANGE BOLT{P/N 90177 - SLo - 000}
12 mm FLANGE NUT
?qRemove the flange bolt. and center the steeringrack.
Wrap vinyl tape around the rack end edges. andcoat the surface of the tape with the power steeringfluid.
NOTE: Make sure that the vinyl tape rs wrappedcarefully so that there is no stepped portion.
Preas

)
41.Coat the inside surface of the new cylinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston'
Push in the cylinder end seal with your finger'
CAUTION: When installing the cylinder end sesl'
be carelul not damage the sealing face ot the seal
with the threads and burrs at the staked position oI
the cylinder housing.
trCYLINDES END SEAL
Replace.Make sure the sPring
is in the cylincler end seal
CYLINDER END
SEAL
Remove the vinyl tape from the steering rack'
NOTE: Remove any residue oftape adhesive
Hold the steering gearbox using a C-clamp as shown'
GEARBOX
C-CLAMP:
l-,
46.
47.
Coat the inside surface of the cylinder end with
power steering fluid, then installthe cylinder end by
screwing it into the cylinder housang.
Remove the C-clamp from the steering gearbox'
After tightening the cylinder end' stake the point of
the cylinder housing shown below For'98 -'00
models go to step 51.
NOTE: Stake the cylinder in the position opposite
from where the stake was removed during disas-
semoly.
Be careful not to damage
the bushing when inserting
the cylinder end.
49. Select the 32 mm shim(s) ('96 -'97 model only)'
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shatt, valve housing, and gear
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
lows.
Shim selection:
a. Set the four 32 mm shims on the bearing surface of
the gearbox housing. Total thickness of the four
shims should equal no more than 0 70 mm'
Shim set: four 32 mm shims (Thickness: 010 mm'
0.15 mm, 0.20 mm, 0.25 mm respectivelyl
CAUTION: Th€ four 32 mm shims do not have
thickness identification marks Measure the thick-
ness of each shim using a micrometsr, and mark
the shim lor identification.
(cont'd)
17-61
Stake point. Depth: 1 0 mm (0.04 in)

Steering Gearbox
Reassembly (cont'd)
b. Install the valve body unit on the gearbox, andtighten the flange bolts to the specified torque.
VALVE BODY UNTTFLANGE BOLT20 N.m {2.0 ksl.m, 14lbI.ftl
Measure the clearance between the gearbox andvalve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midwaybetween the two mounting bolts.
Determine the required thickness of the 32 mmshims by subtracting the clearance obtained in thestep "c" from the total thickness of the four shims.(Total thickness of the 4 shims) - (Clearance) =
Required thickness of the shims
NOTE: Select the shims so that the total thicknessis close to. but less than, the required thickness,
17-62
54.
Example:
Measurement is 0.28 mm (0.011 in):0.70 - O.28 = 0.42 mm (0.028 - 0.011 = O.Ot7 inl
The selected shims should be 0.28 mm lO.OtO in) and0.15 mm {0.006 in} in thickness.
lf the r€quired shim thickness is 0.10 mm or less, noshims are necessarv.
50. Sot the selected 32 mm shims (,96 - ,97 modelsonly) on the bearing surface ofthe gearbox housing.
FLANGE BOLT20 N.m 12.0 ksf.m, 1l lbtftl
VALVE BODY UNIT
'96 - 37 modsl3 only:32 mm SHIMS{S.loctod numb.r of3him!l
Coat ths new O-ring with grease, and carefully fit iton the valve housing.
Apply grease to the needle bearing in the gearboxhousing.
Install the valve body unit on the gearbox housingby engaging the g€ars.
NOTE: Note the valve body unit installation posi-
tion (direction of line connection).
Tighten the flange bolts to the specified torque.
O-RINGReplace.
-A-l
NEEDLE BEARING
-R1
51.
EA