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

Power Steering Gearbox
Disassembly {cont'd}
12. Drill a 3 mm (0.12 in) diameter hole approximately
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the staked
point on the cylinder. Do not allow metal shavings
to enter the cylinder housing. After removing the
cylinder end, remove any burrs at the staked point.
D.oth: 2.5 - 3.0 mm 10.10 - 0.12 inl
CYUNOER
Hold the gearbox using using a C-clamp as shown,
Loosen and remove the cvlinder end.
13.
17-36
14, Assemble a 12 x 1.25 mm flange nut onto a '12 x 175
mm grade 10 flange bolt as shown, Wrap the flange
portion of the bolt with vinyl tape to protect the
cvlinder,
VINYL TAP€ tp/N 90177 - SLO - OOOI 12mmFLANGENUT
Install the flange bolt into the end of the steering
rack until it bottoms in the hole. then back the
flange bolt out 1/4 turn. Hold the flange bolt, and
tighten the flange nut against the rack by hand.
Install the bearing separator on the gearbox housing
as snown.
15.
BEARING SEPARATOR0 - 1112'(Commercially available)
17.
STEERING RACK
CYLINDER €ND
Set the gearbox in a press so the lelt side points
upward, then press the cylinder end seal and steer-
ing rack out of the gearbox. Hold the steering rack
to keep it from falling when pressed clear. Be care-
ful not damage to inner surface of the cylinder
housing with the flange bolt.
www.emanualpro.com

18. Remove the 12 mm bolt and nut trom the stsering
rack,
19. Remove the cylinder end seal from the steering
racK.
20. lnsert a 24" long,3/8" drive extension and the spe-
cial tool into the cvlinder from the left side. Make
sure that the special tool is securely positioned on
the backup ring edges. Be careful not damage to
inner surface of the cylinder with the special tool.
Replace.
I
I
I
CI
24 'LONG 3/8' DRIVE EXTENSION(Commerciallv available)
BACKUP RING
CYLINDER END SEAL
CYLINDER END SEALREMOVER ATTACHMENT07NAD - SR3020A
21.Set the gearbox in a press, then press out the cylin-
der end seal and backup ring from the gearbox.
Note these items when pressing the cylinder end
seat:
. Keep the tool straight to avoid damaging the
cylinder wall. Check the tool angle, and correct it if
necessary, when removing the cylinder end seal.
. Use a press to remove the cylinder end seal. Do
not try to remove the seal by striking the tool. lt
will break the backup ring, and the cylinder end
sealwill remain in the gearbox.
Prass
22. Carelully pry the piston sesl ring and O-ring off the
piston rack. Be careful not to damage the inside of
seal ring groove and piston edges when removing
the seal ring.
Replaco.
(cont'dl
17-37
www.emanualpro.com

Power Steering Gearbox
Disassembly (cont'd)
Valve Body Unit Dbassembly
23. Before removing the valve housing, apply vinyltape
to solines of the Dinion shaft.
VALVE HOUSING
Separate the valve housing from the pinion shafv
valve using a press.
Check the inner wall of the valve housing where the
seal ring slides with your finger. lf there is a step in
the wall, the valve housing is worn. Replace the
valve housing.
Note these items during inspection:
o There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.
. When the valve housing is replaced, install new
shim{s) on the bearing surface of the housing to
adiust the thickness.
Check the inside ofvalve housingfor a step in the wall.
17-38
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 oinion shaft or sleeve
must be replaced, replace both parts as a set.
SLEEVE SEAL RINGSCheck for Deel off or
27. Remove the circlip and sleeve from the pinion shaft.
www.emanualpro.com

28. Using a cutte. or an equivalent tool, cut and remove
the four seal rings from the sleeve. Be careful not to
damage the edges ot the sleeve grooves and outer
surface when removing the seal rings.
Using a cutter or an equivalent tool. cut the valve
seal ring and O-ring at the groove in the pinion
shaft. Remove the valve seal ring and O-ring. Be
careful not to damage the edges of the pinion shaft
groove and outer surface when removing the valve
seal rjng and O-ring.
29.
SLEEVE
Cufting slot position.
30. Remove the valve oil seal and backup ring ('97
model) or wave washer ('98 - 00 models) from the
pinion shaft.
Note these items during disassembly:
. Inspect the ball bearing by rotating the outer race
slowly. lf there is any excessive play, replace the
pinion shaft and sleeve as an assembly.
. The pinion shaft and sleeve are a precise fit; do
not intermix old and new Dinion shafts and
sreeves,
WAVE WASHERl'98 - 0O modelsl
PINION SHAFT
BACKUP RING{'97 modellVALVE OIL SEAL
31.Replace.Press the valve oil seal and roller bearing out of the
valve housing using a hydraulic press and special
tool shown below.
BALL BEARING
PILOT COLLAR
ROLLER SEARING
www.emanualpro.com

Power Steering Gearbox
Reassembly
Note these items during reassembly
. 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 toreign materials to enter the power steering system.
. Use the appropriate specialtools where necessary.
FLANGE BOLTS20 N.m (2.0 kgl.m, 14lbtftl
CYLINDER LINE AFLARE NUTS17 N.m 11.712 rbl.ftl
VALVE HOUSING
CYLINDER END SEALReplace.
VALVE OIL SEALBeplace.
ROLLER BEARING
CIRCLIPReplace.
BA.KUP RING
\/^"
WAVE WASHERBACKUP RINGReplace.97 model:HOUSING
VALVE SEAL RINGReplace.
O.RINGReplace.
32 mm SHIMS'97 mod6l only:
RACK GUIDE SCREW
O-RINGReplace.
@---r-ocxr'rur
'97 model:
'98 model:
'99 - 0O mod6ls:'9? model only:
CYLINDER END69 N.m (7.0 kgf.m, 51 lbf.ft)'98 - (x) models:
PISTON SEAL RINGReplace.
17-40
STEERING RACK
www.emanualpro.com

Valve Body Unh Roa$embly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl tape with
the power steering fluid.
Vinyl tape(Stopp6d portion)
VALVE OIL SEALReplace.Make sure the spring isseated in the oil seal.
Serling
E
7.
PINION SHAFT
BACKUP RING137 modell
WAVE WASHER{'98 - 00 modelsl
Install the backup ring {'97 model) or wave washer
('98 - 00 models).
Coat the inside surface of the new valve oil seal
with power steering fluid.
Install the valve oil seal with its grooved side facing
opposite the bearing, then slide the valve oil seal
over the pinion shaft, being careful not to damage
the sealing lip.
Apply vinyl tape to the splines and stepped ponion
of the shaft, and coat the surface of the vinyl tape
with the power steering fluid.
Vinyl trp€
O.RINGReplace.Do not twist.R€place-Do not over-expand.
Fit the new O-ring in the groove of the pinion shaft.
Then slide the new valve seal ring over the shaft
and in the groove on the pinion shaft,
Remove the vinyl tape from the pinion shaft.
\/
PINION SHAFT
8.Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
Apply power steering fluid to the inside of the spe-
cial tool. Set the larger diameter end of the special
tool over the valve seal ring.
VALVE SEAL RINGSIZNG TOOL07NAG - SR309q'ot07NAG - SR3oltoA
Mak€ the valve seal ringfit snugly in the pinion
shatt using th6 other end{smaller diameter end) otthe special tool.
10.
11.
12.
Move the special tool up and down several times to
make the valve seal ring fit in the pinion shaft,
Remove the soecial tool.
Turn the special tool over, and set the smaller diam-
eter end of the specisl tool over the valve seal ring.
Move the special tool up and down several times to
make the valve seal ring fit snugly in the pinion
shaft.
(cont'd)
lrr.rj1
tffifrE-rr.]
r\-''] 7
Usg th6 larg€r diameterend of the specialtoollirst to maketh€ valve seal ringtit in the pinion
shaft.
17-41
www.emanualpro.com

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
www.emanualpro.com

20. Press the new bearing into the valve housing with
the stamped letter facing up using a hydraulic press
and soecialtool.
ATTACHMENT,32x35mm07746 - 0010100
- ROLLER BEARINGLetter stamped face
21. Apply vinyl tape to the pinion shaft, then coat the
vinyltape with power steering fluid.
Sealing lip tace.VALVE OIL SEAL
VALVE HOUSING
SHAFT
SLEEVE SEAL
PINION
E
22, Insert the pinion shaft into the valve housing. Be
careful not to damage the valve seal rings.
23. Remove the vinyl tape from the pinion shaft, then
remove any residue from the tape adhesive.
8e sure that theseal rings are notturned up, theninstall.
DRIVER
24. Press the pinion shaft/sleeve using a hydraulic
press. Check that the pinion shaft/sleeve turns
smoothly by turning the pinion shaft,
(cont'd)
17-43
www.emanualpro.com

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.
www.emanualpro.com

35. Install the new backup ring on the steering rack,
then place the cylinder end seal against the piston.
BACKUP RINGReplace.
Grease the steering rack teeth, then insert the steer-
ing rack into the gearbox housing, Be careful not to
damage to inner surface of the cylinder wall with
the rack edges.
to.
GEARBOX HOUSING
Prers
37. Install the flange bolt into the end of the steering
fack until it bottoms in the hole, then back the
flange bolt out 1/4 turn. Hold the flange bolt and
tighten the flange nut against the rack by hand.
12 x'175 mm FLANGE BOLT
lP/N 90177 - SLo - 0001
12 mm FLANGE NUT
38.
CYLINDER END SEALReplace.
Install the cylinder end seal into the bottom of the
cylinder by pressing on the bolt with a press, Do notpush on the bolt with excessive force as it may
damage the cylinder end seal.
Remove the flange bolt, and center the steering
rack.
Wrap vinyl tape around the rack end edges, and
coat the surface of the tape with the power steering
fluid. Make sure that the vinyl tape is wrapped care-
fully so that there is no stepped portion.
(cont'dl
ia
40.
17-45
www.emanualpro.com