Pin HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Power Steering Gearbox
Removal
Note these items during removal:
. 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.
. Be sure to remove the steering wheel before discon-
necting the steering joint. Damage to the cable reel
can occur.
. With 4WD. tilt the engine with a jack to expand the
clearance between the transfer assembly and rear
beam when removing the steering gearbox from the
rear oeam.
Do not remove the steering gearbox by removing the
transfer assembly from the transmission.
1. Drain the power steering fluid as described on page'17-15.
Raise the vehicle, and suppon it on safety stands in
the proper locations (see section 1).
Remove the front wheels,
Remove the drive/s airbag assembly {see section 24).
Remove the steering wheel {see page 17-18).
Remove the steering joint bolts, then disconnect the
steering joint by moving the joint toward the column.
UPPER JOINT BOLT
LOWER JOINT BOLT
13.
7. Remove the cotter pin from the nut, and remove the
castle nut {'97 - 98 models) or hex nut ('99 - 00
models).
COTTER PINReplace.
Install the 10 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. Refer to sec-
tion 18 for ball joint remover usage instruction, Be
careful not to damaging the ball joint boot.
Separate the tie-rod ball joint and knuckle using the
special tool.
Remove the right and left tie-rod ends, then extend
the rack all the way to the right.
Remove the TWC (see section 9).
Disconnect the shift linkage from the transmission
(M/T: see section 13, A/T: see section 14).
With 4WD. separate the propeller shaft and transfer
assembly (see section 161.
10.
11.
(cont'd)
17-31
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5. Hold the steering rack with a wrench {'98 - 00 mod-
els: left end onlv), and unscrew the rack end with
another wrench, Be careful not to damage the rack
surface with the wrench,
LOCK WASHER
Loosen the locknut, then remove the rack guide
screw and O-ring ('97 model).
6.
1.
LOCKNUT
Remove the spring and the rack guide from the gear-
DOX.
RACK GUIDE
9.
8. Remove cylinder lines A and B from the gearbox,
CYLINDER LINE A
Drain the fluid from the cylinder fittings by slowly
moving the steering rack back and {orth.
Remove the two tlange bolts, then remove the valve
body unit from the gearbox. (See page 17-38 for
valve body unit disassembly.)
VINYL TAPE
FLANGE BOLT
Apply vinyl tape to stepped portion of the pinion
shaft, and remove the dust cover.(cont'd)
DUST COVER
11.
17-35
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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.
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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
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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
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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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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
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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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Power Steering Gearbox
Reassembly (cont'd)
74. Connect the air tube between the right and left
boot,
CYLINDERLINE A
75. Install the clips on the cylinder lines, then clamp theair tube with the clips.
76. Apply vinyl tape to around the pinion shaft, andcoat the surface of the tape with grease.
DUST COVER
Vinyl Tsp€
VALVE OIL SEAL
VALVE BODY UNIT
Pack the interior of the dust cover and lio withgrease, then install dust cover on the valve bodv unit.
Remove the vinyl tape f.om the pinion shaft.
77.
CYLINDER LINE
17-50
SET RING
't.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot inslalla-
tion section with graase.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ballpin. then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation section and
the tapered section of th€ ball pin.
. Do not allow dust, dirt, or other to.eign materi-
als to enter the boot.
EALL PIN TAPEREDSECTIONWipe olf the grease.
BOOT INSTALLATIONSECTIONWipe offthe grease.
B(X)T IT{STALLATIONsEclroNWipe off the grease.
ADJUSTING BOLTAdiust the depthby turning the bolt.
Install the boot in the groove of the boot installation
section securely. then bleed air.
Adjust the special tool with the adjusting bott untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
I|on.
CAUTION: After installing the boot, chock the batlpin lapered section for grease contamination andwipe it it n€cessary.
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