gearbox HONDA CR-V 1999 RD1-RD3 / 1.G User Guide

Steering Linkage and Gearbox
PINION SHAFT GROMMETInspoct for damage and deterioration.
STEERING JOINTSCheck for loose joint bolts.
NE-ROD LOCKNUTCheck Ior loose locknut.
Inspect for loose mounting bolts.GEARBOX MOUNTING CUSHIONSlnsp6ct for dgterioration.BOOTlnspect for damag€ and d€terioration.
BALL JONT AOOTInspoct lor damage and deterioration.S€e page 17-50 for replacemont.
END AAtL JOINTInspect for faulty movementano oamag€.
17-13
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Rack Guide Adjustment
1.
6.
7.
5.
4.
Set the wheels in the straight ahead position.
Loosen the rack guide screw locknut with the spe-
cialtool, then loosen the rack guide screw.
For'98 - 00 models, remove the rack guide screw.
Remove the old sealant from rack guide screw
threaded section, and apply new sealant to the first
three threads. Loosely install the rack guide screw
on the steering gearbox.
RACK GUIDE SCREW
LOCKNUT25 N.m
12.5 kgt m, 18lbtftl
Tighten the rack guide screw to 25 N.m (2.5 kgf'm,
18 lbf.ft), then loosen it.
Retighten the rack guide screw to 3.9 N'm (0.4
kgf.m, 2.9 lbf.ft), then back it off to specified angle.
Specified Return Anglo:
37 model: 10 r 5"'98 - 00 modeb: 20' Max
Tighten the locknut while holding the rack guide
screw.
Check for tight or loose steering through the com-
plete turning travel.
Perform following inspections:
. Steering operation (see page 17-12).
. Power assist with vehicle parked
Fluid Replacement
Check the reseryoir at regular intervals, and add the rec-
ommended fluid as necessary.
CAUTION: Always use Gsnuine Honda Power Steering
Fluid-V or S. Using any other type of power steering
tluid or automatic transmission fluid can cause increassd
wear and poor steering in cold w3athel.
SYSTEM CAPACITY:
0.85 liter {0.90 US. qt. 0.75 lmp.qtl
at disasssmbly
RESERVOIR CAPACITY:
0.,1 liter (0.42 US. gt, 0.35 lmp.qi)
UPPEN LEVEL LINE
LOWER LEVEL LINE
1.Raise the reservoir. then disconnect the return hose
to drain the reservoir. Take care not to spill the fluid
on the body and parts. Wipe off any spilled fluid at
once.
2, Connect a hose of suitable diameter to the discon-
nected return hose, and put the hose end in a suit-
able container.
3. Stan the engine. let it run at idle, and turn the steer-
ing wheel from lock-to-lock several times. When
fluid stops running out of the hose, shut off the
engine. Discard the fluid.
4. Beinstallthe return hose on the reservoar.
5. Fill the reservoir to the upper level line,
6. Start the engine and run it at fast idle. then turn the
steering from lock-to-lock several times to bleed air
from the system.
7. Recheck the fluid level and add some if necessary.
Do not fill the reservoir beyond the upper level line.
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lnspection and Adjustment
Pump Pressure Gheck With T/N 07406 - 0010001
Check the fluid pressure as follows to determine whetherthe trouble is in the pump orgearbox.
1. Check the powsr steering fluid level (see page 17-15), and pump belt tension (see page 17-14).
2. Disconnect the pump outlet hose from the pump
outlet with care so as not to spill the pow€r steeringiluid on the frame and other pans. thon install theP/S joint adapter (pumpl on the pump outlet.
6 x 1.0 mm BOLT{Part oftool)
FEED HOSE FITTING
PUMP OUTLET HOSE
11 N.m ll.1 kgl.m, E lbf.ftl
P/S PRESSURE GAUGE07('6 - 0010001
6 x t.0 mm BOLT{Part oftool)11 N.m(1.1 kgt m, 8 lbf.tr)
Connect the P/S joint adapter (hose) to the p/S pres-
sure gauge, then connect the pump outlet hose tothe P/S ioint adspter (hose).
Install the P/S pressure gauge to the p/S joint
adapter (pump),
17-16
5. Fully open the shut-off valve.
PRESSURECONTROL VALVE
6. Fully open the pressure controlvatve.
7. Start the engine and let it idle.
8. Turn the steering wheel from lock-to-lock severaltimes to warm the fluid to operating temperature.
9, Measure steady-state fluid pressure while the engineis idling. lf the pump is in good condition, the gauge
should read less than 1,500 kPa (15 kgf/cmr, 213 psi).
lf it reads high, check the outlet hose or valve bodvunit (see General Troubleshooting).
10. Close the pressure control valve, then close theshut-off valve gradually until the pressure gauge
nsedle is stable. Read the pressure.
CAUTION: Do not k€ap tha prca3un control valvoclorod mo.c thon 5 srconds or thc pump cluld bodamEgod by ovor-hoating.
11. lmmodiately open the pressure controlvalve fullv.
lf the pump is in good condition, the gauge shouldread at least 6,900 - 7,800 kpa (70 - 80 kgflcmr,'1,000 - 1.140 psi). A low reading means pump out-put is too low for full assist. Repair or replace theDUMD.
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Pump Pressure Check With T/N 07406 -
Check the fluid pressure as follows to determine whether
the trouble is in the pump or gearbox.
1. Check the power steering tluid level (see page 17-
151, and pump belt tension (see page 17-14).
2. Disconnect the pump outlet hose from the pump
outlet with care so as not to spill the power steering
fluid on the frame and other parts, then install the
P/S joint adapter (pump) on the pump outlet.
6 x 1.0 mm BOLT(Part oftool)
FEED HOSE HfNNG
PUMP OUTLET HOSE
1'l N.m 11.1 kgf.m,8lbf ft)
P/S PRESSURE GAUGE07406 - 001000A
6 x 1.0 mm BOLT(Part ol tool)11 N.m(1.r kg{.m,8lbf'ft|
Connect the P/S joint adapter (hose) to the P/S pres-
sure gauge, then connect the outlet hose to the P/S
joint adapter (hose).
Install the P/S pressure gauge to the P/S joint
adapter (pumpl.
001000A
5. Open the pressure controlvalve fully.
PRESSURECONTROL VALVE
7.
10.
Start the engine and let it idle.
Turn the steering wheel from lock-to-lock several
times to warm the tluid to operating temperature.
Measure steady-state fluid pressure while the engine
is idling. It the pump is in good condition, the gauge
should read 1,500 kPa (15 koflcm',213 psi). lf it reads
high. check the outlet hose or valve body unit {see
General Troubleshooting),
Close the-pressure control valve gradually and read
the oressure.
CAUTION: Do not keep the pressurs control valve
closed more then 5 seconds or the pump could bo
damaged by overheating.
lmmediately open the pressure controlvalve fully.
lf the pump is in good condition, the gauge should
read at least 6,900 - 7;800 kPa (70 - 80 kgflcm',
1,000 - 1.140 psi), A low reading means pump out-
Dut is too low for {ull assist. Repair or replace the
oumo.
17-17
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Power Steering Hoses, Lines
Fluid Leakage Inspection
HOSES and LINES
. lnspect hoses for damage. leaks. interference and twisting
. Inspect fluid linesfor damage, rusting and leakage.
. Check for leaks at hose and line joints and connections.
FEED HOSE37 N.m 13.8 kgf.m, 27 lbtft)RETURN LINE JOINT28 N.m (2.9 kgf.m.21 lbf.ftl
CYLINDER LINES17 N.m (1.7 kgf.m. 12 lbf.ftl
FOWER STEERING PRESSURE SWITCH12 N.m (1.2 kgf.m,8.7 lbtft)
26 N.m (2.7 kgf.m, 20 lbf.ft)
GEARBOX .nd VALVE BODY UNllCheck for leaks at the mating surfaceand flare nut connections.
CYLINDER
FEED HOSE11 N.m('1.1 kgt.m, 8 lbf.ftl
SUCTION HOSE
PUMP ASSEMBLYCheck for leaks atthe pump
seal. inlet and outlet fittings.
Note these items during installation:
. Connect each hose to the corresponding line securely
until it contacts the stop on the line. Install the clamp
or adjustable clamp at the specified distance from the
hose end as shown.
. Check all clamDs for deterioration or deformation;
replace with the clamps new ones if necessary.
. Add the recommended power steering fluid to the
specified level on the reservoir and check for leaks.
ADJUSTABLE HOSE CLAMP: la)
. Position the adjustable hose clamps at the points
indicated by (a) in the drawing above.
. Slide the hose over the line until it contacts the stop.
HOSE CLAMP: lbl
. Position the hose clamps at the
(b) in the drawing above.
. Slide the hose over the line until
Replacement
10.01 - 0.22 in)
points indicatsd by
it contacts the stop,
2.0 - 4.0 mm10.08 - 0.16 inl2.5 - 5.5 mm{0.01 - 0.22 in}17 -23
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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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Power Steering Gearbox
AN'USTABLE HOSE CLAMP
Removal (cont'dl
14. Loosen the 14 mm flare
pump outlet hose.
nut, and disconnect the
14 mm FLARE NUT
15. Loosen the adjustable hose clamp and disconnect
the return hose,
16. Loosen the 16 mm flare nut, and remove the return
hose joint.
17. After disconnecting the hoses and lines, plug or seal
them with a piece of tape or equivalent to prevent
foreign maisrials from entering the valve body unit.
NOTE:
. Do not loosen the cylinder line A and B between
the valve body unit and cylinder.
. With 2WD, continue to step 23.
17 -32
STOP BOLT
10 x 1.25 mm
4WD: Stepr 18-22
18. Removethe right tront mount, then apply vinyl tape
to the side frame to protect it from the transmission
cover and stop bolt.
12 x 1.25 fiiAReplace.
RIGHT FRONT MOUNT
x 1,25 mm
SIDE FRAME
'19. Remove the left front mount, then apply vinyl tape
to the side frame to protect it from the stop bolt.
Vinyltape orequivalgnt material.
Vinyltap€ orequival€nt m6terial.
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REAR MOUNT
20. Remove the rear mount bracket and rear mount.
12 x 1.25 mmReplace.
REAR MOUNT BRACKET12 x 1.25 mmReplace.
21.
14 x 1.5 mmReplaco.
Place a jack under the engine block in the area
shown,
?*
JACK.UP POINT
17-33
22. Jack up the engine and tilt the engine back until the
transfer assembly is lowered approximately 40 mm
(1.57 in).
Note these items when tilting the engine:
. Check that the wire harnesses, hoses and pipes
are not caught by any surrounding parts.
. Do not tilt the engine more than necessary.
ASSEMBLY
Remove the stiffener olate.
NOTE: Some stiffener plate mounting bolts a.e also
used as gearbox mounting bolts. The gearbox will
tilt to the side when these bolts are removed.
(cont'd)
.Lower approximately'40 mm (1.57 in)
STIFFENER PLATE
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Power Steering Gearbox
Removal (cont'dl
24. Remove the mounting brackets.
25.lvlove the steering gearbox to the right so the
rack end clears the rear beam, then place the
rack end below the rear beam.
left
left
Move the steering gearbox to the left, and tilt the
left side down to remove it.
With 4WD. remove the steering gearbox through
the clearance between the transfer assembly and
propeller shaft.
MOUNTING BRACKETS
STEEBING GEARBOX
17 -34
4. Pull the boots away from the ends of the gearbox.
Disassembly
Steering Rack Disassembly
Note these items when disassembling:
. Before disassembling the gearbox, wash it off with
solvent and a brush.
. Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox (see page 17-31).
2. Remove airtube and clips.
3. Remove the boot bands and tie-clips.
AIR TUBE
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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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