1995 ACURA TL Service Repair Manual

9. Coa t th e insid e surfac e o f th e ne w cylinde r en d sea l
with powe r steerin g fluid .
10. Instal l th e cylinde r en d sea l ont o th e steerin g rac k
with it s groove d sid e towar d th e piston .
CAUTION : Whe n installin g th e cylinde r en d seal ,
b e carefu l no t t o damag e th e sealin g li p fac e o f th e
sea l wit h th e edge s o r teet h o f th e steerin g rack .
CYLINDE R EN D SEA LReplace .
PISTON
CYLINDE R EN D SEA LReplace .
13. Greas e th e steerin g rac k teeth , the n inser t th e steer -
in g rac k int o th e cylinde r housing .
CAUTION : B e carefu l no t t o damag e t o inne r sur -
fac e o f th e cylinde r housin g wit h th e rac k edges .
CYLINDE R HOUSIN G
STEERIN G RAC K
14. Inser t 6 " lon g 3/8 " driv e extensio n an d th e specia l
tool int o th e steerin g rac k a s shown .
Press
. 6 " LON G 3/8 " DRIV E EXTENSIO N(Commerciall y available )
CYLINDER EN D SEA L• REMOVE R ATTACHMEN T07NAD-SR3020 A
• STEERIN G RAC K
CYLINDE R EN D SEA L' Replace .
15. Instal l th e cylinde r en d sea l int o th e botto m o f th e
cylinde r b y pressin g o n th e too l with a press a s
shown .
CAUTION : D o no t pus h o n th e too l wit h excessiv e
forc e a s it ma y damag e th e cylinde r en d seal .
STEERIN G RAC K
Groove d side .
Make sur e th esprin g in th e cylinde rend seal .
11. Remov e th e viny l tap e fro m th e steerin g rack .
Remov e an y residu e o f tap e adhesive .
12 . Instal l th e ne w backu p rin g o n th e steerin g rack ,
the n plac e th e cylinde r en d sea l t o piston .
BACKU P RIN G
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Steering Gearbox

Reassembly (cont'd)

CYLINDER END SEAL

Replace.

VINYL TAPE

19. Remove the vinyl tape from the steering rack, then

push in the cylinder end seal with your finger.

NOTE:

• Remove any residue of tape adhesive.

• Take care not to damage the cylinder end seal

with the threads and burrs at the staked position

of the gearbox.

20. Install special to the steering gearbox, then clamp

the tool in a vise with soft jaws as shown.

CAUTION: Do not clamp the cylinder housing.

PULLER YOKE:

(Commercially available)

Snap-On® T/N CJ123-1

OTC® T/N 7372

or equivalent
21. Coat the inside surface of the cylinder end with

power steering fluid, then install the cylinder end by

screwing it into the cylinder housing.

22. Remove the puller yoke from the steering gearbox.

23. After tightening the cylinder end, stake the point of

the cylinder housing shown below.

NOTE: Stake the cylinder in the position opposite

from where the stake was removed during disas-

sembly.

CYLINDER END

CYLINDER END

78 N-m (8.0 kgf-m, 58 Ibf-ft)
BUSHING

Be careful not to damage

the bushing when inserting

the cylinder end.
Grooved side.,
Stake point. Depth: 1.0 mm (0.04 in)

CYLINDER HOUSING

4.0 mm
(0.16
in)

STEERING GEARBOX
16. Wrap vinyl tape around the rack end edges, and

coat the surface of the tape with the power steering

fluid.

NOTE: Make sure that the vinyl tape is wrapped care-

fully so that there is no stepped portion.

17. Coat the inside surface of the new cylinder end seal

with power steering fluid.

18. 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.

Staked position.

Make sure the spring

is in the cylinder end seal.,ProCarManuals.com

24. Selec t th e 4 4 m m shim(s) .
NOTE : Onl y reinstal l th e origina l 4 4 m m shim(s ) whe n
th e steerin g gearbo x i s reassemble d withou t replacin g
th e pinio n shaft , valv e housing , an d gearbo x housin g
wit h ne w ones .
I f th e pinio n shaft , valv e housing , an d gearbo x housin g
ar e replaced , selec t th e ne w shim(s ) a s follows .
Shim selection :
a. Se t th e fou r 4 4 m m shim s o n th e bearin g surfac e o f
th e gearbo x housing . Tota l thicknes s o f th e fou r
shim s shoul d equa l n o mor e tha n 0.7 0 mm .
Shi m set : fou r 4 4 m m shim s (Thickness : 0.1 0 mm ,
0.1 5 mm , 0.2 0 mm , 0.2 5 m m respectively )
CAUTION: Th e fou r 4 4 m m shim s d o no t hav e
thicknes s identificatio n marks . Measur e th e thick -
ness o f eac h shi m usin g a micrometer , an d mar k
the shi m fo r identification .
b. Instal l th e valv e bod y uni t o n th e gearbox , an d
tighte n th e flang e bolt s t o th e specifie d torque .
VALVE BOD YUNITFLANG E BOL T20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
SHIM SET(fou r shims )
c. Measur e th e clearanc e betwee n th e gearbo x an d
valv e bod y uni t usin g a feele r gaug e a s shown .
NOTE : Measur e th e clearanc e a t th e poin t midwa y
betwee n th e tw o mountin g bolts .
FEELE R GAUG E
d. Determin e th e require d thicknes s o f th e 4 4 m m
shim s b y subtractin g th e clearanc e obtaine d in th e
ste p - 3 fro m th e tota l thicknes s o f th e fou r shims .
(Tota l thicknes s o f th e 4 shims ) - (Clearance ) =
Require d thicknes s o f th e shim s
NOTE : Selec t th e shim s s o tha t th e tota l thicknes s
i s clos e to , bu t les s tha n th e require d thickness .
Example :
Measuremen t i s 0.2 8 m m (0.01 1 in) :
0.0 7 - 0.2 8 = 0.4 2 m m (0.02 8 - 0.01 1 = 0.01 7 in )
Th e selecte d shim s shoul d b e 0.2 5 m m (0.01 0 in ) an d
0.1 5 m m (0.00 6 in ) i n thickness .
I f th e require d shi m thicknes s i s 0.1 0 m m o r less , n o
shim s ar e necessary .
25 . Se t th e selecte d 4 4 m m shim s o n th e bearin g sur -
fac e o f th e gearbo x housing .
26 . Coa t th e ne w O-rin g wit h grease , an d carefull y fi t i t
o n th e valv e housing .
27 . Appl y greas e t o th e needl e bearin g i n th e gearbo x
housing.
28. Instal l th e valv e bod y uni t o n th e gearbo x housin g
b y engagin g th e gears .
NOTE : Not e th e valv e bod y uni t installatio n posi -
tio n (directio n o f lin e connection) .
29 . Tighte n th e flang e bolt s to th e specifie d torque .
VALVE BOD Y UNI T
FLANG E BOL T20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
44 m m SHIM S(Selecte d numbe r o fshims )
O-RINGReplace .
NEEDLE BEARIN G
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Steering Gearbo x
Reassembl y (cont'd )
30. Instal l cylinde r line s A an d B .
NOTE :
• Clea n th e joint s o f cylinde r line s A an d B
thoroughly . Th e joint s mus t b e fre e o f foreig n
material .
• Instal l cylinde r line s A an d B by lightin g th e flar e
nut s b y han d first , the n tighte n th e flar e nut s t o
th e specifie d torque .
CYLINDE R LIN E B
CYLINDE R LIN E A
2 0 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
2 6 N- m (2. 7 kgf-m , 2 0 Ibf-ft )
31. Greas e th e slidin g surfac e o f th e rac k guide , an d
instal l i t ont o th e gearbo x housing .
32 . Appl y a thi n coa t o f greas e t o th e ne w O-ring , an d
instal l i t o n th e rac k guid e screw .
33 . Instal l th e spring , rac k guid e scre w an d locknu t o n
th e gearbo x housing .
34 . Adjus t th e rac k guid e scre w (se e pag e 17-5 ).
NOTE : Afte r adjusting , chec k tha t th e rac k move s
smoothl y b y slidin g th e rac k righ t an d left .
RAC K GUID ESCRE W
LOCKNU T
35. Instal l th e ne w loc k washe r i n th e groov e i n th e
steerin g rack .
Cente r lin e o f th eflat section .Roll Pi n Drift , (Snap-o n No . PPR 8
o r equivalent ) COMMERCIALL Y
AVAILABLE
LOCK WASHE R
STEERIN G RAC K
WOOD BLOC K
SLO
T
TUB
36. Scre w eac h rac k en d int o th e rack .
37 . Hol d th e steerin g rac k wit h a wrench , an d tighte n
th e rac k en d wit h another .
CAUTION : B e carefu l no t t o damag e th e rac k sur -
fac e wit h th e wrench .
38 . Afte r tightenin g th e rack , end , stak e th e fou r sectio n
o f loc k washe r wit h th e too l an d a hydrauli c press .
NOTE:
• Plac e th e woo d bloc k o n th e pres s table , the n se t
th e loc k washe r sectio n o f th e rac k en d o n th e
woo d bloc k securely .
• B e sur e th e too l i s aligne d wit h th e fla t section s
o f th e steerin g rac k en d befor e pressing .
• Stak e th e loc k washe r i n th e cente r o f th e fla t
sectio n o f th e steerin g rac k end .
STEERIN G RAC K EN D64 N- m(6.5 kgf-m , 4 7 Ibf-ft )
LOC
K WASHE RReplace.
STAKE POIN T
Flat sectio n o f th e
steerin g rac k end .
Pres s
SPRIN GRAC
K GUID E
O-RIN
G
Replace .
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39. Appl y steerin g greas e t o th e circumferenc e o f th e
rac k en d housing .
STEERIN G GREAS E
RAC K EN D HOUSIN G
RAC K EN D GROOV E
40. Appl y a ligh t coa t o f silicon e greas e t o th e boo t
groove s o n th e rac k ends .
41. Instal l th e boot s i n th e rac k en d wit h th e tub e
clamps .
NOTE : Instal l th e boot s wit h th e rac k i n th e straigh t
ahea d positio n (righ t an d lef t tie-rod s ar e equa l i n
length) .
NOTE: Wip e greas e of fthe threa d section .
SILICON E GREAS E
BOO T
TUBE CLAM P
42. Instal l th e ne w boo t band s o n th e boot s a s shown .
NOTE: Th e Lockin g tab s
(stak e points ) shoul d
b e i n thi s range .
LOCKIN G TAB S
43. Ben d bot h set s o f lockin g tabs .
44 . Lightl y ta p o n th e doubled-ove r portion s t o reduc e
their height .
CAUTION : Stak e th e ban d lockin g tab s firmly .
LOCKIN G TAB S
BOO T BAN D
Replace .
45. Slid e th e rac k righ t an d lef t t o b e certai n tha t th e
boot s ar e no t deforme d o r twisted .
46 . Loosel y instal l th e tie-ro d locknut s an d tie-ro d end s
o n th e rac k ends .
SILICON E GREAS E
Band windin g direction .
Front.
RACK EN D
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Steering Gearbox

Installation

CAUTION: Be careful not to bend or damage cylinder

lines A and B or the four fluid lines when installing the

gearbox.

1. Install the mount cushion on the right side.

2. Loosely install the mounting bracket on the cushion

with the two gearbox mounting bolts.

MOUNT CUSHION

STEERING GEARBOX

GEARBOX MOUNTING BOLTS

38 N-m (3.9 kgf-m, 28 Ibf-ft)

Loosely install.

3. Center the steering rack within its stroke.
4. Install the steering joint, and reconnect the steering

shaft and pinion shaft.

NOTE: Make sure the steering joint is connected as

follows:

a. Insert the upper end of the steering joint onto the

steering shaft (line up the bolt hole with the flat on

the shaft), and loosely install the upper joint bolt,

b. Slip the lower end of the steering joint onto the

pinion shaft (line up the bolt hole with the

groove around the shaft), and loosely install the

lower joint bolt.

Be sure that the lower joint bolt is securely in the

groove in the pinion shaft,

c. Pull on the steering joint to make sure that the

steering joint is fully seated. Then tighten the

joint bolts.

STEERING JOINT
STEERING JOINT BOLTS

2.2 N-m (2.2 kgf-m, 16 Ibf-ft)

UPPER JOINT BOLT

Bolt must line up

with flat on shaft.

Flat portion.

Groove.
STEERING

SHAFT

PINION

SHAFT
STEERING JOINT

LOWER JOINT BOLT

Bolt must line up with

groove around on shaft.

5. Center the cable reel by first rotating it clockwise

until it stops. Then rotate it counterclockwise

(approximately two turns) until the arrow mark on

the label points straight up.

Reinstall the steering wheel (refer to the '95 - 98

Acura 2.5TL Service Manual, P/N 61SW504):ProCarManuals.com

6. Reconnec t th e tw o line s (fee d lin e an d senso r line )
t o th e uppe r sid e o f th e valv e bod y unit .
FEED LIN E
(Fro m th e pump ) 1
1 N- m (1.1kgf-m ,
8 Ibf-ft )
SENSO R RETUR N LIN E
(T o th e reservoir )
7. Reconnec t th e tw o line s (senso r inle t lin e an d retur n
line )
to th e lowe r sid e of th e valv e bod y unit.
SENSO R INLE T HOS E(To th e powe r steerin g
12 m m FLAR E NU T speed sensor )13 N- m (1. 3 kgf-m , 9 Ibf-ft )
1 7 m m FLAR E NU T
2 8 N- m (2. 9 kgf-m , 2 1 Ibf-ft )
RETUR N LIN E
(T o th e reservoir )
8. Instal l th e lin e mountin g cushion s b y alignin g th e
pin k mark s o n th e retur n lin e (larg e diamete r line) .
NOTE : Afte r installin g th e pip e mountin g cushions ,
mak e sur e tha t ther e is n o interferenc e betwee n th e
line s an d rea r beam .
9. Instal l th e tw o lin e clamp s o n th e lin e mountin g
cushions.PINK MARK S
RETUR N LIN E
9.8 N- m(1.0 kgf-m , 7 Ibf-ft )
LINE MOUNTIN GCUSHIONS
LIN E CLAM P
NOTE: Mak e sur e tha t ther e is n o interferenc e betwee n
th e flui d lines , th e rea r bea m or an y othe r parts .
10 . Tighte n th e tw o gearbo x mountin g bolt s o n th e
righ t sid e tha t wer e loosel y installe d in ste p 2 .
11 . Instal l th e splas h guar d wit h th e tw o gearbo x
mountin g bolt s o n th e lef t side .
12 . Tighte n th e splas h guar d attachin g bolts .
NOTE : Instal l th e bolt s loosel y first , the n tighte n
SPLAS H GUAR D
GEARBO X MOUNTIN G BOLT S
5 9 N- m (6. 0 kgf-m , 4 3 Ibf-ft )
SPLAS
H GUAR D MOUNTIN G
BOLTS38 N- m (3. 9 kgf-m , 2 8 Ibf-ft )
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Steering Gearbo x
Installatio n (cont'd )
13. Reconnec t th e tie-ro d end s t o th e steerin g knuckles ,
tighte n th e castl e nu t t o th e specifie d torque , an d
instal l ne w cotte r pins .
NOTE : Befor e connectin g th e tie-ro d ends , chec k
th e bal l join t pi n tapere d sectio n an d thread s sec -
tio n fo r greas e contamination , an d wip e i t i f neces -
sary.
CAUTION : Torqu e th e castl e nu t t o th e lowe r
torqu e specification , the n tighte n it onl y fa r enoug h
t o alig n th e slo t wit h th e pi n hole . D o no t alig n th e
nu t b y loosening .
14 . Instal l th e fron t wheels .
15 . Fil l th e syste m wit h powe r steerin g fluid , an d blee d
ai r fro m th e syste m (refe r t o th e '9 5 - 9 8 Acur a
2.5T L Servic e Manual , P/ N 61SW504) .
16 . Afte r installation , perfor m th e followin g checks .
• Star t th e engine , allo w it t o idle , an d tur n th e
steerin g whee l fro m lock-to-loc k severa l time s t o
war m u p th e fluid . Chec k th e gearbo x fo r leaks .
• Adjus t th e fron t to e (se e sectio n 18 ).
• Chec k th e steerin g whee l spok e angle . Adjus t b y
turning the righ t an d lef t tie-rods , i f necessary .
NOTE : Tur n th e righ t an d lef t tie-rod s equally .
CASTLE NU T49 - 5 9 N- m(5. 0 - 6. 0 kgf-m , 3 6 - 4 3 Ibf-ft )
COTTE R PI NReplace .On reassembly , ben d
th e cotte r pi n a s shown .
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