HONDA INTEGRA 1998 4.G Workshop Manual

Power Steering Gearbox
Removal (cont'd)
Remove the cotter pin from the ball joint pin and
remove the nut.
Install the 10 mm hex nut on the ball ioint.
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 ball joint re-
mover.
NOTE: Remove the ball joint using the special tool.
Refer to section 18 for the ball joint remover usage
instructions.
Separate the tie-rod ball ioint and knuckle using the
special tool.
CAUTION: Avoid damaging th. ball ioint boot.
t{ePrace. BALL JOINT REMOVER,23 mm07MAC - SL0020o
10. Disconnect the shift linkage (M/T model: see section
13, A,/T model: see section 14).
11. Disconnect the secondary heated oxygen sensor
(H02Sl connector, and separate the three way cat-
alytic convener by removing the self-locking nuts.
NOTE: Always replace the gaskets with new ones.
SECONDARy HEATED OXycEN SENSOR SELF-LOCKING NUT
17 -42
Replace.CATAI.YTIC CONVERTER
12.
13.
Remove the return line clamp from the left side of
the rear beam, and move the return line above the
steering gearbox.
Remove the rear beam brace rod.
Remove the left tie-rod end. then slide the rack all
the way to the ri9ht.
14.
RETURN LINE CLAMP
LEFT NE-ROD END

15. Disconnect the two lines from the valve bodv unit
on the steering gearbox.
CAUTION: After disconnscting the hose and line,plug or seal the hose and lino whh I pi6ce ot tape
o. oquivalent to prevont foreign matarials from
6rioring the vslve body unit,
NOTE:
. Place the line disconnected in the previous steD
at the rear side of the gearbox so that they do
not hinder in the gearbox removal.
. Do not loosen the cylinder lines A and B between
the valve body unit 8nd cvlinoer.
ADJUSTABLE HOSE CLAMP
Remove the steering gearbox mounting bolts.16.
\
RETURN HOSE
GEARBOX MOUNTING BOTTS
17-43
't7.
19.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead, and remove thepinion shaft grommet.
Move the steering gearbox to the right so th€ left
rack end clears the rear beam.
Mov€ the steering gearbox to the loft, and tilt theleft side down to remove it from the vehicle.
PINION SHAFT GBOMMET
STEERING GEARBOX

Power Steering Gearbox
Disassembly
Steering Rack Disa3sembly
NOTE:
. Before disassembling the gearbox, wash it off with
solvent and a brush.
. Do not dip seals and O-rings in solvent.
L Remove the steering gearbox (see page 17-41).
2. Remove the air hose and clips.
3. Remove the tie-rod end and locknut,
Remove the boot bands and tube clamps. Pull the
boots away from the ends of the gearbox.
TUBE CLAMP
CLIP
BOOT
17-44
SPRING
5. Hold the left end of the steering rack with a wrench
and unscrew the rack end with a wrench.
TIE-ROD LOCK WASHERBePlace
Loosen the locknut and remove the rack guide
screw.
Remove the spring and rack guide from the gearbox
housing.
7.
RACK GUIDEscnEw
,s*LOCKNUT
RACK GUIDE

8.Remove the cylinder line A and B from the gearbox.
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 17-47 for
valve body unit disassembly.)
FLANGE BOLT
10.
CYLINDER LINE B
VAI.VE BODY UNIT
11.Orill 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: Oo not allow metal shavings to enter the
cylinder housing.
12. Install a puller yoke to the steering gearbox. Clamp
the puller yoke in a vise with soft jaws as shown,
then loosen and remove the cvlinder end,
CYLINDER END
STAKED POINT
\\
i D.pth:2.5 - 3.0 mm {0.10 - 0.'12 inl
re
17-45l

Power Steering Gearbox
Disassembly (cont'dl
VINYL TAPE
12 mmFLANGE NUT
13. Set the gearbox in a press so the gearbox housing
pornts upward.
14. 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.
15. Press the cylinder end seal and steering rack out of
the gearbox.
NOTE: Hold the steering rack to keep it from falling
when pressed clear.
T-
I
I170 mm
CYLINDEREND SEAL
Remove the flange bolt and cylinder end seal from
the steering rack.
Press
t
18.
17.
Ple3s
I
ATTACHMENT, 23 x 25 mm
07NAD - SR3020A
CYLINDER ENDSEAL
19. Carefully pry the piston seal ring and O-ring off the
oiston of the rack.
CAUTION: Be carelul not to damage the inside of
seal ring groove when remoying the seal ring.
lnsert a 24" long, 3/8" drive extensjon, and the spe-
cial tool into the cylinder from the gearbox side.
CAUTION: Be careful not to damage the inside sur-
lace of the housing with the lools.
Set the gearbox in a press, then press out the cylin-
der end seal and backup ring from the gearbox.
CAUTION:
. Keep the tool straight to avoid damaging the
cylinder wall, Chcck thc tool angle, and correct il
necessary, when removing the cylinder end s€al.
. Use a press to remove the cylinder end seal. Do
not try to remove the seal by striking the tool. lt
will brcak the backup ring and the cylinder end
seal will remain in the gesrbox.
Replace
17-46

20.Apply vinyl tape to the pinion shaft.
Separate the valve housing from the pinion shaft/
valve ustng a press.
VALVE HOUSING
Vinyllape
PINION SHAFT
Check the inner wall of the valve housing where the
seal ring slides with your finger. It there is a step in
the wall, the valve housing is worn, Beplace the
valve housing.
NOTE: There may be the sliding marks trom the
seal ring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.
21.
22.
23. 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 pinion shalt or sleeve
must be replaced, replace the both parts as a set.
SLEEVE SEAL RINGSCheck for peel off ordamage.
24. Remove the circlip and
pinion shaft,
pinion shaft sleeve from the
(cont'd)

Power Steering Gearbox
Disassembly (cont'd)
25. Using a cutter or an equivalent tool, cut and remove
the four seal rings from the sleeve.
CAUTION: 86 caroful not to damage the edgos of
the 3leeve grooves whon removing the scal rings
and O-ring.
Using I cutter or an equivalent tool, cut the valve
seal ring and O-ring at the groove the pinion shaft.
Remove the valve seal ring and O-ring.
CAUTION: 86 careful not to d.mago the sdges ol
lhe pinion shaft groove whgn removing the valvo
seal ring and O-ring.
SLEEVE
Cutting slot position.
17 -48
t"fRemove the valve oil seal and wave washer ring
from the pinion shaft.
NOTE:
. Inspect the ball besring by rotating the outer
race slowly. lf there is 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 pinion shafts and
steeves.
VALVE OII- SEALReplace.
Press the valve oil seal and bushing out of the valve
housing using a hydraulic press and special tool
shown below.
ATTACHMENT, 23 x 25 mm
07NAD - SB3020A
VALVE OIL SEALReplace.
28.
BALL EEARING
BUSHING

ra
NOTE:
. Clean the disassembled parts with a solvent and dry them with compressed air. Do not dip the rubber parts in a sol-
venr,
. Always replace the O-rings and rubber seals with new ones before assembly,
. Apply recommended power steering fluid to the parts indicated in the assembly procedures.
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.
. Use the appropriate specialtools where necessary.
FLANGE BOLT20 N.m 12.0 kgf.m, 14 lbl.ftl
VALVE HOUSING
CYLINDER LINE B26 N.m 12.7 kgf.m, 20
VALVE OIL SEALReplace.
SLEEVE SEAL RINGSReplace.st"cEvE
VALVE SEALReplace.
WAVE WASHER
VALVC SEAL RINGReplace.
O-RINGReplace.
PINION SHAFT
RACK GUIDE SCREW
LOCKNUT \
cEARBoxHousrNc \b
SPRING
f,ACK GUIDE
BACKUP RING
Replace.
GEAR HOUSINGCYLINDER ENDReplace.
CYLINDER END SEALReplace.O.RINGReplace.
I
o0'
STEERING RACK
PISTON SEAL RINGReplace.
CYLINDER END69 N.m {7.0 kgtm,51 lbtftl
{cont'd}

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.

12.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. Do two rings at a time from
each end of the sleeve.
NOTE:
. 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. Oo not mix the different types of
sleeve seal rings as they are not compstible.
Align the special toolwith each groove in the sleeve.
and slide a sleeve seal ring into each groove.
NOTE: After installation, compress the seal rings
with your fingers temporarily.
BALL JOINT B(X)? CUP GUIDE07MAG - SLdrlrx,
Apply power steering fluid to the seal rings on the
sleeve and to the entire inside surface of the soecial
tool.
SLEEVE SEAL NINGSIZING TOOL0r9?a - sat02n0
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.
NOTE: Be sure that the seal ringsare notturned up.
13.
14.
to.
17-51
Cutout.
17.Apply power steering fluid to the surface of the pin-
ion shaft, assemble the sleeve over the pinion 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:
. Be careful not to damage the valve seal ring
when inserting the sleeve.
. Install the circlip with its radiused side facing in,
18. Installthe circlip securely in the pinion shaft groove.
Apply power steering fluid to the seal ring lip of the
valve oil seal. Then install the seal in the valve
housing using a hydraulic press and special tools as
snown.
CAUnON: Instsll tho valvo oil s€.| with its groovcs
side facing th. tool.
19.
ATTACHMET{T,32x35mm077i15 - (xll01lX,
VALVE OIL SEALReplace.Make sure thespring in theoilseal.
(cont'd)