PC box HONDA CIVIC 1998 6.G Manual Online

Steering Gearbox
)
Removal
NOTE: Using solvent and a brush, wash any oil and dirt
off the valve body unit its lines. and the end if the gear-
box. Blow dry with comPressed air.
1. Drain the power steering fluid as described on page
2. Raise the front of vehicle, and support it on safety
stands in the proper locations (see section 11.
3, Remove the front wheels.
4. Remove the driver's airbag assembly, and steering
wheel (see page 17-35)
5. Bemove the steering joint cover.
6. Remove the steering joint lower bolt, and loosen
the steering joint upper bolt. Disconnect the steer-
ing joint by moving the ioint toward the column
tJ
17-47
TIE.ROD END
7. Remove the cotter pin from the castle nut {'96 -'97
models) or nut ('98 - '00 modslsl and remove the nut.
BALL JOINT REMOVER.28 mm07MAC - SLqI2|X)
'98 - '00 mod.b:NUT
8.
COTTER PINSRepl6ce.
lnstall the t0 mm hex nut on the ball joint.
Be sure that the 10 mm hex nut is flush with the ball
joint pin end, or the threaded section of the ball
joint pin might be damaged by the special tool.
NOTE: Remove the ball joint using the special tool.
Refer to section 18 for how to use ths ball joint
remover.
Seoarate the tie-rod ball joint and knuckle using the
specialtool.
CAUnON: Avoid damaging tho ball ioint boot.
Remove the left tie-rod end, then slide the rack all the
way to the right.
Separate the exhaust pipe A or TWC (see section 9).
Disconnect the shift linkage (see section 13 or section
14).
(cont'd)
9.
10.
11.
12.

Steering Gearbox
Removal {cont'dl
Loosen the 14 mm flare nut and disconnect the feed
line.
Loosen the adjustable hose clamp and disconnect
the return hose.
Loosen the 16 mm flare nut and remove the return
hose joint trom the valve body unit.
CAUTION: After disconnecting lhe hos6 and lin6.
plug or seal the hose and line with a pioca ol tapa
or equivalent to prevenl foreign matorials trom
entsring the valve body unit.
NOTE: Do not loosen the cvlinder line A and
between the valve body unit and cylinder.
ADJUSTABLE HOSECLAMP
Remove the stiffener Dlate.
NOTE: Some stiffener plate attaching bolts are also
used as gearbox mounting bolts. The gearbox will
tilt to side when these bolts are removed.
13.
14.
t9.
16.
17-48,
17. Remove the mounting brackets.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead. then remove the
pinion shaft grommet.
Move the steering gesrbox to right so the left rack
end clears the rear beam, then tilt the left side down
to remove it from the vehicle,
CAUTION: Be careful not io bend or damage the
fagd ling and cylindsr lin99 whgn rgmoving thg
ggarbox,
18.
STEERING GEANEOX

)
Disassembly
t)
Steering Rack DisassemblY
NOTE:
r Before disassemble the gearbox, wash it off with sol
vent and a brush.
. Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox (see page 17-47]..
2. Remove the tie-rod end and locknut.
3. Remove air tube and cliPs.
Remove the boot bands and tie-rod clips Pull the
boots away from the ends of the gearbox.
BOOT
(|-,TIE.ROD CLIP
Hold the steering rack with a wrench ('98 -'00 mod-
els: left end only), and unscrew the rack end with
another wrench.
CAUTION: Be caroful not to damage the rack 3ur-
faco whh the wrench.
NOTE: '96 -'97 models is shown.
STEERING RACK END
STEERING RACK
Loosen the locknut, then remove the rack guide
screw and O-ring ('96 -'97 models only)
Remove the spring and the rack guide from the gear
housing.
7.
{cont'd}
17 -49
LOCK WASHER

Steering Gearbox
Disassembly (cont'd)
8. Remove cylinder lines A and B from the gearbox.
CYLINDER LINE gCYLINOCR LINE A
Drain the fluid from the cylinder fittings by slowly
moving the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body unit from the gearbox. (See page 17-52 forvalve body unit disassembly.)
VALVE BOOY UNITFLANGE BOLT
10.
'96 - '97 mod.ls:32 mm SHIMS98 - '00 modok:WAVE WASHER
17-50
13. Loosen and remove the cvlinder end.
11. Drill a 3 mm (0.12 in) diameter hole approximatety
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the stakedpoint on the cylinder.
cAunoN:
o Do nol allow metal shavings to onter the cylin.
der housing.
. After romoying iha cylinder end, remova any
bur6 at the staksd point.
Dcpthi 2,5 - 3.0 mm {0.10 - 0.12 in}
CYUNDER
12. Hold the steering
snown.
gearbox using a C-clamp as

t
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.

Steering Gearbox
Disassembly (cont'd)
30. Bemove the valve oil seal and backup ring {'96 -'97
models) or wave washer ('98 -'00 models) from theoinion shaft.
NOTE:
. Inspect the ball bearing by rotating the outer race
slowly. lf there is any excessive play, replace thepinion shaft and sleeve as an assembly.
. The pinion shaft and sleeve are a precise fit; do
not intermix old and new pinion shafts and
steeves.
'98 - '(x) mod.lr:WAVE WASHERReplace.
31.Press the valve oil seal and roller bearing {'96 -,97
modelsl or bushing ('98 -'00 modelsl out of thevalve housing using a hydraulic press and specialtool shown below.
NOTE: Do not use a hammer; it will damage the
specialtool.
'96 - '97 modob:
PILOT COLLAR07GAF - PH70100
VAI.VE OIL SEALReplace.
BOI.I"ER BEARINGReplace.
PILOT COLLAR07GAF - PHtoroo
VALVE OII. SEALReplace.
BUSHINGBeplace.
BALL BEARING
'96 - '00 mod.b:
17-54

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.

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 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