1994 HONDA INTEGRA Workshop Manual

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)

60.
Install the new lock washor in the groov€ in the
steering rack.
Hold the steering rack with I wrsnch and tighten
the rack end.
After tightening th€ rack end, stske the four sections
of lock washer with a commercially available roll
Din drift and a mallet.
ROLL PIN DRIFTComm.rcl.lly Av|il.bl.
lsnrp-On No. PPR8 or .rquiv.lenll
NOTE: This drift has a fl8t,
to prevent puncturing
of motal washer.
ol
62.Apply steering groass to the circumferenc6 of tho
rack end housing.
Coat the rack end groove and inside of the boot
with silicone greas€.
lnstsll the boots in ths rack end with the tube
clamos.
NOTE: Install the boots with the rack in the straight
ahsad position (i.6. right and l€ft tis-rods ar€ squal
in length).
(cont'dl
64.
NOTE: Wipe ths gro.se offthe thread s€ction.
TUEE CLAJTIP
17-61

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.

lnstallation
CAUTION; BG Glrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1. Before installing the gearbox, slide the rack all the
way to right.
2. Pass the right side of the steering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack all the
wav to the left.
4. Raise 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 bulkhead.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodv.
6. Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
hose connactions for interference with adjacent
pans.
58 N.m 15.9 kg[.m, $ lbl.ftl
TAA
38 N m 13.9 kgl.m, 28 lbt.ftl
17-63
YELLOW GEAR TOOTH
7.Center the steering rack within its stroke.
Make sure that the cable reel of the SRS is centered
as follows:
. Turn the steering wheel left approx. 150 degrees,
to check the cable reel position with indicator.
. lfthe cable reel is centered. the yellow gear tooth
lines up with the alignment mark on the cover.
. Return the steering wheel right approx. 150
degrees to position the steering wheel in the
straight ahead position.
ALIGNMEi'IT MARK
Slip the lower end of the steering joint 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 ioint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
. lf the steering wheel and rack are not centeted,
reposition the serralions at lower end of the
steering joint.
(cont'dl
22 N.m 12.2 kgi.m, 16lbf.ftlLOWER BOLT

Steering Gearbox
Installation (cont'd)
10. Install the steering joint cover with the clamps andcliDs.
STEERING JOINT COVER
11. Connect the fluid lines to the valve bodv unit.
CLIP
RETURN HOSE
17-64
38 N.m 13.9 kg{.m, 28 lbf.ft)
12. Install the rear beam brace rod and return pipe
clamp on the rear beam.
NOTE: Install the rear beam brace toward thereturn pipe clamp.
13. Install the three way catalytic converter with thenew gaskets and new self-locking nuts, and connectthe heated oxygen sensor (H02S) connector,
HEATED OXYGEN SENSOR CONNECTOF
SELF.LOCKING NUT33 N.m 13.4
SELF.LOCKING NUT22 N.m (2.2 kgt m, 16 lbt.ftl
14. Connect the shift linkage (M/T model: see section
13, A/T model: see section 14).

15.Thread the right and lefi tie-rod ends onto the rack
an eoual number of turns.
TIE-ROO ENDTIE.ROD LOCKNUT
R€connect the tie-rod ends to the steering knuckles,
tighten the castle nut to the specified torque, and
install new cotter pins.
CAUTION: Iorquo tho castle nut to tho lower tor-
que lpocification, thsn tighton it only far cnough to
align thc slot with tho pin hole. Do not align tho
nut by loosoning.
CASILE NUT39 - 47 N.m14.0 - a.8 kgf.m. 29 - 35 lbf ftl
17. lnstallthe front wheels.
18. Fill the system with pgwer steering fluid and bleed
air from the system (see page 17-21).
19. After installation. perform the following checks.
. Check the gearbox Jor leaks (see page 17-231
. Adjust the front toe (see section 18).
o Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate ihe boot in3talls-
tion section with gr€aso.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ball
pin, then pack the lower area with fresh grease.
CAUTION:
. Ke€p g;eass off the boot in3tallation section and
tho laperad section of the ball pin.
. Do not altow dust, di.t, or other toreign mat6ti-
als to enter tho boot,
LIPBALL PIN TAPEREDSECTIONWipe off the grease.
BOOT INSTALLATIONSECTIONwiDe off the grease.
BOOT INSTALLATIONSECTIONWipe off the grease.
COTTER PINOn reassembly, bendthe cotter pin as shown.
Install the boot in the groove ot the boot installation
section securely, then bleed air.
SALL JOINT BOOTCLIP GUIDE07MAG - SL(x)l00Adiust the depth byturning the tool.
SET RING
Insert the special tool into the threads in the ball pin
and align the end of the tool with the groove in the
boot.
Slide the clip over the tool and into position
CAUTION: After installing the boot, check th. b.ll
pin taperod section tor grease contamiration and
wipe it if nocossary.
NE.ROD END
Turn the right and left tie-rods equally.
17-65