gearbox HONDA INTEGRA 1994 4.G Owner's Manual

Steering Gearbox
Disassembly
Stssring Rack Disassembly
NOTE:
. 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 17-45).
2. Remove the air hose and clips.
3. Remove the tie-rod end and locknut.
4. Remove the boot bands and tube clamps. Pull the
boots away from the ends of the gearbox.
CLIP
BOOT
5. Hold the steering rack with a wrench and unscrew
the rack end with a wrench.
Loosen th6 locknut and remove tha rack guide
screw.
Ramove the spring and rack guide from the gear
housing.
7.
LOCKNUTRACK GUIDE
17-48,
TUBE CLAMP

Remove the cylinder pipe A and B from the gear-
box.
Drain the fluid from the cylinder fittings by moving
the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body unit from the gearbox. {See page 17-51 for
valve body unit disassembly.)
FLANGE BOLT
CYLINDER PIPE B
VALVE BODY UNIT
11.Drill a 3 mm {0.12 in) diameter hole approximately
2.5 - 3.5 mm (0.10 - 0.14 in) in depth in the staked-
point on the cylinder.
NOTE: Do not allow metal shavings to enter the
cylinder housing.
STAKEO POINT
D.prh:2.5 - 3,0 mm 10.10 - 0.12 inl
CYUNDER END
12. Install a puller yoke to the stesring gearbox. Clamp
the puller yoke in a vise with soft iaws as shown,
then loosen and remove the cvlinder end.
PULLER YOKE:Commercirlly AvrilabloSn.p-Ono T/N qrie'-1
oTclo T/N 7372
(cont'd)
17-49

Steering Gearbox
Disassembly lcont'd)
13, Set the gearbox in a press so the gear housing points
upward.
14. Installthe flange bolt into the end ofthe steering rack
until it bottoms in the hole, then back the flange bolt
out 1/4 turn. Hold the tlange bolt and tighten the
flange nut against the rack by hand.
15. Press the cylinder end seal and steering rack out of
the gearbox,
NOTE: Hold the sreering rack to keep it from talling
when pressed clear.
VINYL TAPEPre$
I
12 mmFLANGE NUT
STEERINGGEARBOX
16.Remove the soecial tool and cylinder end seal lrom
the steering rack.
17-50
17.
CYLINDER ENOSEAL
18.
Remove the 12 mm bolt and nut from the steering
rack, then install a 24" long.3/8" drive extension, and
the special tool into the cylinder from the gearbox
side.
CAUTION: Be caretul not to damagc th€ in3idr
surface ot ths housing with tho tool3.
Set the gearbox in a press, then press out the cylinder
end seal and backup ring trom the gearbox.
CAUTION:
Ksep the tool straight to avoid damagingtha cYlind.r
wall. Chsck tis tool angls, and corr€st if nrcolrary,
whsn rsmoving the cylinder end seal.
Use ! prors to r6movo tho cylinder end rgal. Do not
try to remove the soal by 3triking ths tool. h will
break the brckup ring and tho cylind€r end leal will
romain in ths gsarbox.
2it" LONG 3/8" DRIVE EXTENSION:Comm€rcirlly Availobl.
CYLINDER END SEALREMOVER ATTACHME?ST
19. Carefully pry the piston seal ring and O-iing off the
piston of the rack.
CAUTION: Be careful not to damags th€ insidc ot
seal ring groove whgn romoving th€ seal ring.
Replace.

Steering Gearbox
Disassembly (cont'dl
25. Using a cutter or an equivalent tool, cut and remove
the four seal rings from the sl6eve.
CAUTION: Bc clroful not to drmrg. ths .dgc. otthc alcava g1oov6 whan rcmoving the 3cd rings
lnd O.ring.
Using a cutter or an gquivalent tool, cut the valve
seal ring and O-ring Et the groove the pinion shaft.Remove the valv€ saal ring 8nd O-ring,
CAUTION: Br crrltul not to drm.gr thc cdgct ofthc plnion rhdt grooya whcn rcmoving the vllvc
!.!l ring rnd O-ring.
26.
SI-EEVE
Cutting slot position.
17.52
Remova the valve oil seal 8nd backup ring from thepinion shaft.
NOTE:
. Inspect the ball bearing by rotating the outer
race slowly. lf thsre is excessive play, replace thepinion shaft and sleeve as an assembly.. The pinion shaft and sleeve are a precise fiu donot intermix old and new pinion shafts and
steev8s,
28, Press th6 valve oil s€al and roller besring out ofthe
valve housing using a hydraulic press and specialtool shown below.
PILOT COLLARO?GAF - PHTO1OO

Steering Gearbox
Reassembly lcont'd)
Vllvc Body Rea3sombly
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 tluid,
2. Install the backup ring with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil seal
with power steering fluid.
4. Slide the valve oil seal over the pinion shaft. being
careful not to damage the sealing lip.
CAUTION: ln3tall the valve oil ssal with hs groovad
3ide tacing opposits the besring.
Vinyl trpolst.ppcd ponion,Tapered position.
Groove side.
VALVE OIL SEAL
Fit the new O-ring in the groove of the pinion shaft.
Then slide the new valve seal ring over the shaft
and groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft.
NOTE: Do not over - expand the valve saal ring.
S€aling
E
lip
PINION SHAFT
VALVE SEAL RING
17-54
7. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
8. 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.
9. Move the special tool up and down several times to
make the valve seal ring Jit in the pinion shaft.
10. Remove the special tool.
.11. Turn the special tool over and setthe smallerdiam-
eter end of the special tool over the valve seal ring.
Move the sDecial tool uD and down severai times to
make the valve seal ring snugly fit in the pinion
shaft.
VALVE SEAL RING
(H(ffi
Use the wider diameterend ot the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringsnugly fit in the.pinionshaft using the other end(smaller diameter end) ofthe specialtool.

Steering Gearbox
Reassembly (cont'd)
SI,-EEVE SEAL RINGSBe sure that thesear ings are notturned up, theninstall.
Press the new roller bearing into the valve housing
using a hydraulic press and special tool as shown.
NOTE: Place ths roller bearing on the valve hous-
ing with its letter stamped facing up towards the
valve side.
Pr.33,
I
PINION
E
20.
ATTACHMENT,32x35mm077/aO - (x)1010O
ROLLER BEARINGLetter stamped face
21.Apply vinyl tape to the pinion shaft, then coat thevinyl tape with power steering fluid.
Insert the pinion shaft into the valve housing.
CAUTION: Be carotul not to damage tho valvs soalrings.
23. Remove the vinyltape from the pinion shaft.
Soaling lip frc..
VALVE OIL SEAL
VALVC HOUSING
17-56
24. Press the pinion shaft/sleeve using a hydraulic
Dress as shown.
CAUTION: Before irserting the pinion 3haft, bosuro that the backup ring is csntored with the pin.
ion shaft bearing,
BACKUP BING

Steering Gearbox
Reassembly lcont'dl
34. Separate the cylinder end seal from the spscial tool,then remove the tool from the steering .ack.
lnstall the backup ring on the steering rack, thenplace the cylinder end seal to piston.
Grease the steering rack teeth, then insert the steer-ing rack into the gear housing.
CAUTION: Be clrs{ul not to d.mage to inn9r !ur-ftca of thc goar housing with th€ rsck cdg6.
CYUNDER END SEAL
BACKUP RING
CYLINDER END SCAL
17-58
CYUNDER END SEAL
37.
'to
Set lhe gearbox in a press with the cylindor housing
facing upward.
Install the flange bolt into the end of the steering rack
until it bottoms in the hole, then back the flang€ bolt
out 1/il turn. Hold the flange bolt and tighten the
flange nut against the rack by hand.
Install the cylinder end seal into the bottom of the
cylinder by pressing on the bolt with a press as
shown.
CAUTION: Do not push on ihc bolt with excelcivr
forcc; 83 it may dEmago thr cylindor ond 3o!1.
Pr9!t
I
12 x 170 mm FLANGE BOLT
12 mm FLANGE NUT
STEERING RACK
CYUNDER END SEAL
41.
Remove the flange bolt and center the steering rack.
Install the special tool or vinyl tape onto the end ofthe steering rack, then coat the special tool or vinyltape with power steering fluid.
Coat the inside surface of the new cylinder end sealwith power steering fluid.
Install the cylinder end seal onto the ste€ring rackwith its grooved side toward the piston.
Remove the special tool. Push in the cylinder endseal with finger.
NOTE: Take care not to damage the cylinder endseal with the threads and burrs at the stakod oosi-tion of the gearbox.St k d po3ition.
c.oov.d3id...--#

IL ll

41.
Install a puller yoke to the steering gearbox, then
clamp the puller yoke in a vise with soft jaws as
shown.
PULLER YOXE:Commcrcirlly AvrihbloSn.p-Ono T/N Cr123-lorco T/N 7372or aquivrlani
Grease the inside surface of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der housing.
After tightening the cylinder end, stake the point of
the cylinder housing shown below.
NOTE: Stake in the cylinder in the position opposite
from where the stake was removed during disas-
semblv.
Strke point, D.pth: 1.0 mm (0.04 inl
4.0 mm 10.15 inlCYLINDER HOUSING
CYLINDER END
CYLINOER69 N.m 17.0 kgf.m, 51 lbtft)
,t8. Select the 32 mm shim(s).
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-
rows.
Shim r€lection:-'1. Set the four 32 mm shims on the b€aring surface of
the gearbox housing. Total thickness of the four
shims should eoual no more than 0.70 mm.
Shim set: tour 32 mm shims (Thickness: 0.10 mm,
0.15 mm, 0.20, 0.25 mm respectivelyl
CAUTION: The tour 32 mm shimr do not hlva
thlckn$s idcntitication mukt. Mo!3ur. tho thicl-
oa33 of rach 3him using a miclomctrl, and mlrk
tho shim lor id6ntific8tion.
-2. Install the valve body unit on the gearbox, and
tighten the flange bolts to the specitied torque
VALVE BODY UNIT
FLANGE BOLT20 N.m {2.o kgtm, 14lbt'ftl
SHIM SET{foul thim.)
Measure the clearance between the gearbox and
valve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midway
between the two mounting bolts.
(cont'd)
17-59

Steering Gearbox
Reassembly lcont'd)
-4. Determine the requifed thickness of the 32 mm
shims by subtracting the clearance obtained in thestep -3 from the total thickness of the four shims.(Total thickness of the 4 shims) - (Clearance) =
Required thickness of the shims
NOTE: Select the shims so that th6 total thicknessis close to, but less than the required thickness.
Exampls:
Measu.ement is 0.28 mm (0.011 in):
0.70 - 0.28 = 0.42 mm (0.028 - 0.011 = 0.0't7 in)
The selected shims should be 0.25 mm (O.O1O in) and0.15 mm (0.005 in) in thickness.
lf the required shim thickness is 0.lO mm or less, no
shims are necessary.
i[9. Set the selected 32 mm shims on the bearing sur-face of the g€arbox housing.
50, Coat the new O-ring with gresse and install it in thegroove in the gearbox housing.
Apply grease to the needle bearing in the gearbox
housing.
Install the valve body unit on the gearbox housing
by engaging the gears.
NOTE: Note the valve body unit installation posi-
tion (direction of pipe connection).
Tighten the flange bolts to the specified torque.
FLANGE BOLT20 N.m (2.0 kgt m, 14lbf.ft)
VALVE BODY UNIT
ct.
O-RING
-ffiti
NEEOLE BEARING
_#{
17-60
BACK GUIDE SCREW
54. Installthe cylind6r pipes A and B.
NOTE:
. Clean the joints ofthe cylinder pipe A and B tho.-oughly. The joints must be free of foreign mat€.i-
at,
o Install the cylinder pipe A and B by tighting theflare nuts by hand first, then tighten the flarenuts to the specified torque starting with thecylinder side nuts.
CYLINDER PIPE B
Grease the sliding surface of the rack guide andinstall it onto the gear housing.
Apply a thin coat of grease to the n€w O-ring andinstall it on the rack guide screw.
Install the spring, rack guide screw and locknut onthe gear housing.
Adjust the rack guide screw (see page l7-21).
NOTE: After adjusting, check that the rack movessmoothly by sliding to rack right and left.
LOCKNUT
-6t
26 N.m (2.7 kg{.m,20lbtft)

Steering Gearbox
Reassembly (cont'dl
65. Adjust the air hose fitting position of the boots by
turning it as shown below.
Front
AIR HOSE FITTING
Connect the air hose between the right and left
boot. then install the clips on the cylinder pipe B assnown.
Install the right clipin this position.
CLIP
17-62
67.Install new boot bands on the boot and bend both
sets of locking tabs.
Lightly tap on the doubled-over portions to reduce
their height.
GAUTION: Stake tho band locking tabs firmly.
Slide the rack right and left to be certain that the
boots are not detormed or twisted.
Install the right and left tie-rod ends on the rack
ends.
70.