spring HONDA CR-V 1998 RD1-RD3 / 1.G Workshop Manual

Power Steering Gearbox
13.
Reassembly (cont'd)
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. Install two rings at a time
Jrom each end ofthe sleeve.
Note these items when installing the seal ring:
. Do not over-expand the seal ring. Install the 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.
Align the special tool with each groove in the sleeve,
and slide a sleeve seal ring into each groove. After
installation, compress the seal rings with your fin-
gers temporarily.
BALL JOINT BOOT CLIP GUIDE07974 - SA508q)
SLEEVE
Apply power steering fluid to the seal rings on the
sleeve, and to the ehtire inside surface of the special
tool.
14.
15.
SLEEVE SEAL RINGSIZING TOOL07974 - SA502O0 or07974 - SA5020A
16.Insert the sleeve into the special tool slowly.
Move the sleeve each direction several times to
make the seal rings snugly fit in the sleeve. Be sure
that the seal rings are not turned up,
't1.
18. Apply power steering fluid to the surface of the pin-
ion shaft. Assemble the sleeve over the Dinion 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 these items during reassembly:
. Be caretul not to damage the valve seal ring
when inserting the sleeve.
. Install the circlip with its radiused side facing out.
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. Install
the valve oil seal with its grooved side facing the tool.
19.
ATTACHMENT,32x35mm077i16 - (x)10100
VALVE OIL SEALReplace.Make sure thespring is in theoilseal.
CIRCLIP
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Power Steering Gearbox
Reassembly (cont'dl
Stecring Rack R8assembly
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 ring on
the sDecial tool, then slide them down toward the
big end of the tool.
Note these items during reassembly:
a Do not over expand the resin seal rings. Install
the resin seal rings with care so as not to dam-
age them. After installation, be sure to contract
the seal ring using the special tool (sizing tool).
a Replace the piston's O-ring and seal ring as a set.
27. Pull rhe O-ring off into the piston groove, then pull
the piston seal ring off into the piston groove on top
of the O-ring.
Coat the piston seal ring and the inside of the spe-
cial tool with power steering fluid.
07GAG - SO4O200 orOTGAG - SD'()2OA
Carefully slide the tool onto the rack and over thepiston seal ring.
Move the special tool back and fonh several times
to make the piston seal ring fit snugly in the piston.
24.
PISTONReplace
E
30.
PISTON
17-44
31. Wrap vinyl tape around the rack teeth and rack end
edges, then coat the surface of the tape with the
power steering fluid. Make sure that the vinyl tape
is wrapped carefully so that there is no stepped por-
tion.
Coat the inside surface of the new cvlinder end
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston. When
installing the cylinder end seal, be careful not dam-
age the sealing lip face of the seal with the edges or
teeth of the steering rack.
CYLINDER END SEAL
Make sure thespring is in lhe cylindereno seal
Remove the vinyl tape from the steering rack, then
remove any residue from the tape adhesive.
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Power Steering Gearbox
Reassembly (cont'dl
4l. Coat the inside surface of the new cvlinder end seal
with power steering fluid.
CYLINDEB ENO SEALReplace.Make sure the springis in the cylinder end seal.
43.
Stakedposrtron.
Grooved side.
42. 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.
When installing the cylinder end seal, be careful not
damage the sealing face of the seal with the threads
and burrs at the staked position of the cylinder
housing.
Remove the vinyl tape from the steering rack, then
remove any residue from the tape adhesive.
Hold the gearbox using a C-clamp as shown.
GEARBOX
44.
45.
C.CLAMP
17-46
46.Grease the inside surtace of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der.
Remove the C-clamp from the gearbox.
After tightening the cylinder end, stake the point of
the cylinder shown below. Stake the cylinder in the
position opposite from where the stake was removed
during disassembly,
NOTE: For '98 - 00 models, go to step 54.
41.
48.
BUSHING
-tGCYLINDER END69 N.m (7.0 kgf.m,51 lbtft)8e careful not to damagethe bushing when insertingthe cylinder end.
49. Select the 32 mm shim(s) ('97 model onlv).
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shaft. 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:
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: 0.10 mm, 0.15
mm, 0.20 mm, 0.25 mm respectively)
NOTE: The four 32 mm shims do not have thickness
identification marks. Measure the thickness of each shim
using a micrometer, and mark the shim for identification.
Stake point, Depth: 1,0 mm (0.04 inl
4.0 mm {0.16 in)
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Power Steering Gearbox
Reassembly (cont'dl
58. Installthe cylinder lines A and B
Note these items during reassembly:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by hand first, then tighten the flare
nuts to the soecified torque.
CYLINDEF LINE A
Grease the sliding surface of the rack guide, and
install it onto the gear housing.
For'97 model, apply a thin coat of grease to the new
O-ring, and install it on the rack guide screw.
For'98 - 00 models. remove the old sealant from
the threads of the rack guide screw. then apply new
sealant to the first three threads.
-6rO-RING
nlcr cutDE R"Pl""u'
SCREW
LOCKNUT
37 model:
60.
ot.
38 model:
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17,15). After
adjusting, check that the rack moves smoothly by
sliding the rack right and left.
17 N.m 11.7 kgd.m, 12lbf.ttl
26 N.m {2.7 kgl.m, 20
RACK GUIOE
17-48
STEERING RACK
(
63. Install the new lockwasher in the groove in the
steering rack.
LOCK WASHERReplace.
STEERING RACK ENO54 N.m (5.5 kgf.m,40 lbtftl
64.
STEERING
Screw the rack ends into the rack.
Hold the steering rack with a wrench ('98 - 00 mod-
els: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
wrench.
After tightening the rack ends, stake the four sec-
tions of lock washerwith a drift and a mallet.
. Place the wood block on the press table, then set
the lock washer section of the rack end on the
wood block securely.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing.
. Stake the lock washer in the center of the flat
section of the steering rack end,
ROLL PIN PUNCH
lCommorcially.Y.il.blelSnap-On No. PPR8 or oquival.nt.
NOTE: This drift has a flatshoulderto preventpuncturing of metal washer.
WOODEN BLOCK
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Disassembly/ Inspection
Disass.mbly
1. Compress the damper spring with a spring com-
pressor according to the manufacturer's instruc-
tions, then remove the self-locking nut. Do not com-press the spring more than necessary to remove the
nur.
10 mm SELF-LOCKINGReplace.
STRUTCOMPRESSOR:lComm6rcially availablo)BRANICK@ T/N MST-580Aor Mod6l 7200or equivalent
Release the pressure from the spring compressor,
then disassemble the damper as shown in the next
cotumn.
Inspection
1.Reassemble all parts, except for the spring.
Push on the damper assembly as shown.
Check for smooth operation through a full stroke,
both compression and extension. The damper
should move smoothly. lf it does not (no compres-
sion or no extension), the gas is leaking, and the
damper should be replaced.
Check for oil leaks, abnormal noises, or binding dur-
ing these tests.
2.
29 N.m (3.0 kgl.m,22lbtftlReplace.
DAMPER MOUNTING WASHER
DAMPER MOUNTING
SELF-LOCKING NUT10 x 1.25 mm
RUBBERCheck forano oamage.
DAMPER MOUAMNG COLLAR
DAMPER MOUNTINGBASE
DAMPER MOUNTINGRUBBERCheck for det€riorationano oamage.
BUMP STOP PLATE
DUSTCheckfor bending and damage.
..rgBUMPSTOP g
weakness anddamage,
SPRING MOUNTING
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Front Damper
Reassembly
1. Install the damper unit on a spring compressor.
STRUT SPflNG COMPBESSOR:lcomm.rcillly .vrilrble)BRANICKC T/N MST.sEOAor Mod.l 7200or oquivtla
SPRING LOWER SEAT
Assemble the damper in reverse order of removal
except the damper mounting washer and self lock-
ing nut. Align the bottom of the damper spring and
the spring lower seat as shown.
Position the damper mounting base on the damper
unit as shown.
Compress the damper spring,
Install the damper mounting rubber, damper mount-
ing washer, and a new 10 mm self-locking nut.
SELF-LOCKING NUT10 x 1.25 mmZt N.m 13.0 kgf.m, 22 lbf.ft)Replace.
Hold the damper shaft, and tighten the
locking nut.
DAMPERMOUNfING WASHER
18-18
10 mm self-
1.
lnstallation
Loosely install the
aligning tab facing
two flange nuts.
damper on the frame with
inside, then loosely install
FLANGE NUT
the
tne
-__---a-"- 10 x 1.25 mmg*- 59 N.m {5.0 kgt m, 43 tbf.ftl
| -,./.46- --...
./ -4 A-
DAMPERASSEMBLY
ALIGNINGTAB
2, Install the damper fork over the driveshaft and onto
the lower arm. Install the front damper in the
damper fork so the aligning tab is aligned with the
slot in the damDer fork,
3. Loosely install the damper pinch bolt on the top of
the damper fork.
4. Looselv install the damper fork bolt and a new self-
locking nut on the bottom of the damper fork.
5. Raise the knuckle with a floor iack until the vehicle just
lifts off the safetv stand.
The lloor iack must b€ socurely posi-
tioned or personal iniury may result.
6. Tighten the damper pinch bolt.
7. Tighten the damper fork bolt and self-locking nut.
8. Tighten the flange nuts on top of the damper.
9. Install the brake hose mounts with the brake hose
mounting bolts.
10. Installthe front wheel.
10 x 1.25 mmil3 l+m
{4.4 kgf'm,
Replace.
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Rear Damper
Disassembly/lnspection
Disassembly
L Compress the damper spring with the spring com-
pressor according to the manufacturer's instruc-
tions, then remove the self-locking nut. Do not com-
press the spring more than necessary to remove the
self-locking nut.
SELF-LOCKING NUT10 x 1.25 mmReplace.
STRUT SPRINGCOMPRESSOR:lCommercirlly avaihblo)BRANICKO I/N MSI-580Aor Mod6l/7200 or equivalent
2. Release the pressure from the spring compressor,
then disassemble the damper as shown on page 18-
25.
Inspection
1. Reassemble all parts, except the spring.
2. Push on the damper as shown.
3.
WOODEN ELOCK
Check for smooth operation through a full stroke,
both compression and extension. The damper
should move smoothly. lf it does not (no compres-
sion or no extension), the gas is leaking, and the
damper should be replaced.
Check for oil leaks, abnormal noises, or binding dur-
ino these tests.
4.
SELF-LOCKING NUT10 x 1.25 mm
OAMPERMOUNTINGWASHER
29 N.m {3.0 kgf.m, 22 lbf.ft)Beplace.
OAMPER MOUNTINGRUBBERCheck fordeteriorationano oamage.
DAMPER MOUNTINGCOLLAR
DAMPERMOUNTING BASE
DAMPER MOUNTINGRUBBERCheck fordeteriorationano oamage.
'"dd"^.s"'
//F,
DAMPERCheck for weakness,compressron
DUST COVER PLATE
DUST COVERCheck for bendingand damage.
SPRING MOUNTINGRUBBERCheck Ior deteriorationand damage.
BUMP STOPCheck for weaknessano oamage.
DUST COVEN BOOTCheck for deterioralionano oamage.
BUMP STOP PLATE
DAMPER
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Reassembly
1.Install the damper unit on a spring compressor,
Assemble the rear damper in reverse order of disas-
sembly except the damper mounting washer and
self-locking nut. Align the bottom of the damper
spring and the spring lower seat as shown.
2.
DAMPER MOUNNNG
STRUT SPBING COMPRESSOR:(Commorcislly !v.ilablelBRANICKC T/N MST.s8OA
3.Position the damper mounting base on the damper
unit as shown.
Compress the damper spring with the spring com-
pressor.
Install the damper mounting washer, and loosely
install a new self-locking nut.
SELF.LOCKING NUT10 x 1.25 mm29 N.m (3.0
Replace.
Hold the damper shaft with a hex wrench, and tight-
en the self-locking nut.
1.
lnstallation
Lower the rear suspenston,
damper. The spring stop on
should face rearward, and the
left damper should face forward.
and position the
the right damper
sprang stop on the
SPRING STOP
2. Loosely install the two flange nuts.
FLANGE NUTS10 x 1.25 mm . .:{9 N.m 15.0 kgf.m, 36 lbtft}- :',,-rigf't"n if'"""_nrr. in ----.-*
qla^ 7Step 7.
3. Loosely install the flange bolt.
FLANGE EOLT10 x 1.25 mm54 N.m 15.5 kgt.m,40 tbI.ft)
6.
7.
8.
Raise the rear suspension with a floor jack until the
vehicle just lifts off the safety stand.
@ The floor iack must be securely posi-
iioned or personal iniury may result.
Tighten the flange bolt.
Tighten the two flange nuts on the top of the
damper to the specified torque.
Install the damper cap and access panel.
Check the rear wheel alignment. and adjust if neces-
sary (see page 18-4).
18-25
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Front Brake Caliper
Disassembly/Reassembly
. Never use an air hose or dry brush to clean brake assemblies.
. Use an OSHA approved vacuum cleaner to avoid breathing brake dust.
. Contaminated brake discs or pads reduce stopping ability.
. When reusing the pads, always reinstallthe brake pads in their original positions to prevent loss ol braking efficiency.
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme-
diatelY with water.
NOTEI
. To prevent spills, cover the hose joints with rags or shop towels.
. Clean all pans in brake fluid and air dry; blow out all passages with compressed air.
. Before reassembling, check that all parts are free of dust and other foreign particles.
. Replace parts with new ones whenever specified to do so.
. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
. Do not reuse the drained fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the
life of the system.
. Coat the piston, piston seal, and caliper bore with clean brake fluid.
. ReDlace all rubber oarts with new ones whenever disassembled.
. After installing the front brake caliper do the following.- Check for leaks at hose and line joints and connections, and retighten if necessary.- Check the brake hoses for interference and twistinq.
SHIM
12 mm FLANGE BOLTS113 N.m (11.5 kgtm,83lbf.ftlINNER
ft
il1
#
\i
#
PIN B
OUTER PAO SHIM
PAD SPRING
IPIN BOOT
-Cr
SEALING WASHERSReplace.4dd*
ERAKE PADS
'f,-rre
/ tto*l "o"\
t@I
/\'
sLreo 6cnew \I N m 10.9 kStm, 6.5 lbnft)
\
6-
>PIN A
-6, {
CALIPER BOOY
CALIPER EOLTS49 N.m {5.0 kgl.m, 36lbf.ftl
PISTON AOOTReplace.
"..-a=a-...,--"sEqriPISTON
t".:jil,,.'.1!!!!9!il: Rubber grease (Use recommended grease in the caliper set)
irf"i:;;T::fl,-J'I",0 .@
--6, Silicone grease (use recommended seal grease and p,n grease in the caliper set)
INNER SHIM BWEAB INDICATOR
EANJO BOLT34 N.m {3.5 kgf m,25 lblftl
PISTON SEALReplace.
AFACKET
19-12
PAD RETAINERS
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Rear Drum Brakes
Never use an air hose or dry brush to clgan brake assemblies,
Use an OSHA approved vacuum cleaner to avoid breathing brake dust.
Contaminated brake linings or drums reduce stopping ability.
Block the front wheels betore iacking up lhe rear ot the vehicle,
Block the front wheels, loosen the rear wheel nuts slightly, then raise the
poned. Remove the rear wheels.
2. Release the parking brake, and remove the rear brake drum.
I N.m {0.9rbr.ft)kgl.m,5.5
\\
\
196
@
Inspection
a
a
rl
a
1.vehicle, and make sure it is securely sup-
BACKING PLATEMarked left and right.
PARKING EBAKE I-EVERMarked left and right.
ADJUSTER BOLTCheck ratchet teethfor wear and damage.UPPER RETURN SPRINGCheck for weaknessand damage.
CLEVIS BCLEVIS A
64 N.m 16.5 kgl.m,47 lbt.ftl
\L;
SPRINGCheck for weaknessano oamage.
'l-'-' u-cllP
I Replace.
t/
6d/
BRAKE SHOEInspection, see page 19 17lf brake shoes are to bereused, mark and reassemblein same position.
WHEELInspect for leakage.Replacement, seepage 19-20
LOWER RETURNSPRINGCheck for weaknessano oamage.
RETAINER SPRINGInstall securely onlensron prn.
19-16
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