gearbox HONDA INTEGRA 1998 4.G Owner's Manual

Power Steering Gearbox
Reassembly (cont'dl
i
valv6 Body Reasrombly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl tspe with
the power steering fluid.
Vinyl tlp€lst.ppcd ponionl
Groov€ side.
Install the wave washer,
Coat the inside surface of the new valve oil seal
with power steering fluid.
Slide the valve oil sesl over the pinion shaft, being
careful not to damage the sealing lip.
CAUTIONT ln3tall the v8lve oil 3eal whh itr groovod
side facing oppositc thc braring.
Fit the new O-ring in the groovo of the pinion shaft.
Then slide the new valve sesl 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 seal ring.
Sr.lino
E
lip
VALVE SEAL RINGReplace.Do not over-expand.
17-50
7. Apply power steering fluid to the surJace 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.
Move the sDecial tool uo and down several times to
make the valve seal ring fit in the pinion shaft.
11.
(w(ffi \
Use the wider diameter Make th6 valve seal ringend of the special snugly fit in the pinion
tool first to make shaft using the other endthe valve seal ring (smaller diameter end) ofIit in the pinion the special tool.shalt.
Remove the special tool,
Turn the special tool over and set the smaller diam-
eter end of the special tool over the valve seal ring,
Move the special tool up and down several times to
make the vslve seal ring snugly fit in the pinion
shaft.

Power Steering Gearbox
Reassembly (cont'dl
20. Press the bushing into the valve housing using a
hydraulic press and speciai tool as shown.
DRIVER07749 - U)l 0000
ATTACHMENT,32x35mmPress
I07746 - fi)l01(x)
sUSHING
21.Apply vinyl tape to the pinion shaft, then coat the
vinyl tape with power steering fluid.
I
i
I
VALVE OIL SEALReplace.
VALVE HOUSING
Vinyltape
PINION
E
SITEVE SEAL RINGSReplace.8e sure that theseal rings are notturned up, theninstall.
Insert the pinion shaft into the valve housing.
CAUTION: Be careful not to damage the valve seal
rings.
Remove the vinyl tape from the pinion shaft.
Seding lip lrce.
17-52
24. Press the pi.ion shafvsleeve into the valve housing
using a hydraulic press as shown.
NOTE: Check that the pinion shaft/sleeve turns
smoothly by turning the pinion shaft with your
hand.

Power Steering Gearbox
Reassembly {cont'd}
34. Separate the cylinder end seal from the special tool,
then remove the tool from the steerino rack.
CYLINDER END SEALReplace.
lnstall the backup ring on the steering rack. then
place the cylinder end seal to piston.
Grease the steering rack teeth, then insert the steer-
ing rack into the gearbox housing.
CAUTION: Be carelul not to damage to inner sur-
tace of the gearbox housing with the rack edges.
BACKUP BING
CYLINDER END SEAL
17-54
37.
38.
Set the gearbox in a press with the cylinder housing
facing upward.
Install the flange bolt into the end of the steering
rack until it bottoms in the hole. then back the
tlange bolt out 1/4 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 th€ boh with excossive
lorce; as it may damage thecylinder end seal.
Press
I
12 x 170 mm FLANGE BOLT
12 mm FLANGE NUT
Wrap vinyl tape around the rack end edges, and
coat the surface of the tape with the power steering
flu id.
NOTE: Make sure that the vinyl tape is wrapped care-
fully so that there is no stepped ponion.
Coat the inside surface of the new cvlinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston.
CAUTION: When installing the cylinder end seal,
be careful not to damage the sealing lip face of the
seal with the edges of the steering rack,
Stak6d oosition.
39.
41.
Make sure the springis in the cylinder end

Remove the vinyl tape from the steering rack, then
push in the cylinder end seal with your finger.
NOTE:
. Remove any resideue of tape adhesive.
. Take care not to damage the cylinder end seal
with the threads and burrs at the staked position
of the gearbox.
Install a puller yoke to the steering gearbox, then
clamp the puller yoke in a vise wjth soft jaws as
shown.
PULLER YOKEI{Commcrci.lly .vailablelSn.p-On@ T/N c.r123-1oTc€ T/N 7372or equivalent
Grease the inside surface of the cylinder end. then
install the cylinder end by screwing it into the cylin
der,
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-
semory.
Stake point. Dopth: 1.0 mm (0.04 inl
4.0 mm (0.16 inl
CYLINOER END
46.
\
47.
49.
coat the new o-ring with grease and install it in the
groove in the gearbox housing.
Apply grease to the needle bearing in the gearbox
ho using.
Install the valve body unit on the gearbox housing
by engaging the gears. Tighten the flange bolts to
the specified torque.
NOTE: Note the valve body unit installation posi-
tion (direction of pipe connection).
VALVE BODY UNIT
(cont'd)
O.RINGReplace.
-611
NEEDLE AEARING
-Grl
17-55

Power Steering Gearbox
Reassembly (cont'dl
Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder line A and B thor-
oughly. The joints must be free ol foreign materi-
at.
. Install the cylinder line A and B by tightening the
flar€ nuts by hand first, then tighten the flare
nuts to the specified torque staning with the
cylinder side nuts.
CYLINDER I-INE B26 N.m {2.7 kgf.m, m lbl.ftl
50.
5t.Grease the sliding surface of the rack guide
install it onto the gearbox housing,
and
52.
53.
LOCKNUT
q
SPRING
RACK GUIDE SCREW
Install the spring, rack guide screw and locknut on
the gearbox housing.
Adjust the rack guide screw (see page 17-2'll,
NOTE: After adiusting, check that the rack moves
smoothly by sliding to rack right and left.
17-56
STEERING RACK
WOODEN BLOCK
54.Install the new lock washer in the groove in the
steering rack.
Screw each rack end into the rack.
Hold the left end of the steering rack with I wrench
and tighten to th€ rack ends with another.
56.
After tightening the rack end, stake the four sections
of lock washer with a commerciallv available rollpin drift and a mallet.
RACK END5{ l{.m
{5.5 kgl.m, aO lbt.ftl
ROLL PIN DRIFTlcomm.rci.lly .v.ihbl.l(Sn.pon f{o, PPR8 or .quiv.lc.n}
LOCK WASHERReplace.
NOTE: This dritt has ato prevent puncturingot metal washer.

Power Steering Gearbox
Reassembly (cont'dl
63. 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.
CAUTION: Stake ihe bsnd locking tabs tirmly.
Slide the rack right and ieft to be certain that the
boots are not deformed or twisted.
Install the right and left tie-rod ends on the rack
enos.
64.
lnstallation
CAUTION: Bo caretul not to bond or damrge the powcr
steering lines when in3t8lling the grlrbox.
1. Before installing the gearbox, slide the rack all the
way to right.
2, Pass the right side of the stsering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack 8ll the
way to the right.
4. Rsise the left side of the steering gearbox above
and through the left side of the rear beam.
5. Install the pinion shaft grommet and insert the pin-
ion shaft up through the bulkhesd.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodY.
oo.
tAa
17-58

Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
tube connections for interference with adjacent
parts.
58 N.m 15.9 kgl.m, 43 lbf.ftl
Connect the power steering fluid lines to the valve
body unit.
7.
38 N.m {3.9 kgt m, 28 lbf.ftl
RETURN HOSE
PUMP OUTI.TY HOSE(High-pressure)
37 N.m (3.8 kgf.m, 27 lbt.ftl
Center the steering rack within its stroke.
Before connecting the steering joint, perform the
lollowing operation.
. Center the cable reel by first rotating it clockwise(approximately two turns) until the arrow mark
on the label points straight up,
Slip the lower end of the steering ioint onto the pin-
ion shaft {line up the bolt hole with the groove
around the shaft), and tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.
. Be sure that the lower steering joint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
o lf the steering wheel and rack are not centered,
reoosition the serrations at lower end of the
steering joint.
(cont'd)
LOWER BOLT22 N.m {2.2 kgf.m, 16 lbf.ft,
17-59

Power Steering Gearbox
Installation (cont'dl
11. Install the steering joint cover with the clamps and
clips.
lnstall the rear beam brace rod and return line
clamp on the rear beam.
NOTE: lnstall the rear beam brace toward the
return line clamp.
12.
CLIP
38 N.m 13.9 kgl'm,28 lbf tl)
17-60
13. Install the three way catalytic converter with the
new gaskets and new self-locking nuts, and connect
the secondary heated oxygen sensor (HO2S) con-
nector.
SECONOARYHEATED OXYGEN SENSOR CONNECTOR
22 N.m {2.2 kgf.m, 16lbIft)
Connect the shift linkage (M/T model: see section
13, A,,/T model; see section 14).
Thread the right and left tie-rod ends onto the rack
an equal number of turns.
14.

)
)
16.Reconnect the tie-rod ends to the steering knuckles,
tighten the nut to the specified torque, and install
new cotter Dins.
COT?ER PINReplace.On reassembly, bendthe cotter pin as shown.
lnstall the front wheels.
Fill the system with power steering fluid and bleed
air from the system (see page 17-21).
After installation, perform the tollowing checks.
. Check the gearbox for leaks (see page l7-23).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods equally, it nec-
essary.
Ball Joint Boot Replacement
CAUTION: Do not contaminste th! boot in3tllhtion sec-
tion with grca3o.
1. Remove the boot from the tie-rod end, and wiDe the
old grease off the bsll pin.
2. Pack the lower area of the ball pin with fresh grease.
3. Pack the interior of the new boot and liD with Jresh
grease.
CAUTION:
r Keep grease off tho boot inst.llrtion section 8nd
ths tapered 3cction if tho ball pin.
. Do not lllow du3t. dirt. or other foreign matcrials
to entar lh6 boot.
17.
18.
Lfp -A-1
L:I
ru
Install the new boot using the special tool as shown
Derow.
NOTE: The boot must not be a gap at the boot instal-
lation sections.
CAUTION: Aftor installing tho boot, chock tho ball
pin tapgrgd 3oction tor grorsg conttmination, and
wipe it if nccossary.
BALL PIN TAPEREDsEcnoNWipe offthe grease.BOOT INSTALLATIONsEcnoNWipe off the groaso.
19.
FROI{T HUBDIS/ASSEMBLY TOOL07965 - SA5o5o0
17-61

MEASUREMENTSTANDARD (NEWI
Steering wheelRotational play at steering wheel circumferenceStarting load at steering wheel circumferenceN (kgf, lbf) Engine running
0 - 10 (0 - 0.39)
34 (3.5,7 .71
GearboxAngle of rack-guide-screw loosened from lockedoosition20'MAX
PumpPump pressure with shut-off valve closedkPa (kgf/cm,, psi)6,400 - 7,400 (65 - 75, 924 - 1,067],
Power steeringfluidRecommended fluidFluid capacity GSR, Type Rf (US qt, lmp qtl cS, RS, LSReservoir
Honda Power Steering Fluid-V or S1.06 (1.12,0.93)
1.0 (1.06,0.88)
0.4 (0.42, 0.35)
Power steeringbelt*Deflection with 98 N (10 kgf,22 lbflbetween pulleys1 1.5 - 13.5 (0.45 - 0.531 with used belt8.0 - 10.0 (0.31 - 0.39) with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge390 - 540 (40 - 55, 88 - 120) with used belt740 - 880 (75 - 90, 170 - 2001with new belt
SteeringSection 17
* When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.Readiust deflection or tension to used belt values.
Suspension - Section 18
BrakeSection 19
Unit of length: mm (in)
$t
MEASUREMENTSTANDARD (NEWI
WheelalignmentCamber Front Type RAll except Type RRearCaster FrontTotal toe FrontRearFront wheel turning angle Inward wheelOutward wheel
-0'30'r 1"-0' 10'r 1.-0" 45'1?:i3i1. 10'1 1.0!210!1116!,lN 2 lf (t7t6 1 1716136. 00'1 2"30'30'
Wheel bearingEnd play FrontRear0 - 0.05 (0 - 0.002)0 - 0.05 (0 - 0.002)
WheelRim runout (Aluminum wheel) AxialRadialRim runout (Steel wheel) AxialRadial
STANDARD (NEW}SERVICE LIMIT
0 - 0.7 (0 - 0.03)0 - 0.7 (0 - 0.03)0 - 1.0 (0 - 0.04)0 - 1.0 (0 - 0.04)
2.0 (0.08)
1.5 (0.06)2.0 (0.08)1.5 (0.06)
MEASUREMENTSTANDARD (NEW}
Parking brakeleverPlay in stroke at 196 N (20 kgf,44 lbf)lever forceLocks when oulled 6 -10
notches
Foot brakepedalPedal height (With floor mat removed)
Free play
M/TAtT160 (6 5/161165 rc 1nl1-5(1/16-3/16)
Master cylinderPiston-to-oushrod clearance0 - 0.4 (0 - 0.021
Disc brakeDisc thickness Front Type RAll except Type RRearDisc runout FrontRearDisc parallelism Front and rearPad thickness Front Type R
All except Type RRear Type RAll except Type R
STANDARD (NEWISERV]CE LIMIT
22.9 - 23.1 (0.90 - 0.91120.9 - 21.1 (0.82 - 0.83)
1= t (0.35-0.361
10.5 - 11.5 (0.41 - 0.45)9.5 - 10.5 (0.37 * 0.41)8.5 - 9.5 (0.33 - 0.37)7.0 - 8.0 (0.28 - 0.31)
21.0 (0.83)19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)1.6 (0.06)
1.6 (0.06)1.6 (0.06)
1.6 (0.06)