1996 ACURA RL KA9 light

19. Clea n th e rin g gea r teeth , the n pain t the m lightl y an d
evenl y wit h Prussia n Blu e (o n bot h side s of eac h
tooth) .
20 . Instal l th e differentia l carrie r int o th e differentia l
case , an d reinstal l th e differentia l cas e cover .
21 . Instal l th e bolt s an d tighte n in a crisscros s patter n in
severa l steps .
Torque : 4 4 N- m (4. 5 kgf-m , 3 3 Ibf-ft )
22. Instal l th e specia l too l a s shown . Rotat e th e driv e
pinio n i n bot h direction s s o tha t th e rin g gea r rotat e
on e ful l tur n i n bot h directions . Durin g thi s opera -
tio n resistanc e shoul d b e applie d to th e rin g gear .
LOCKNU T SOCKET ,36 x 41 m m07HAA-SF1010 0
DRIVEPINIO N
Remov e th e specia l tool , an d us e a dial-typ e torqu e
wrenc h o n th e driv e pinio n t o chec k tota l bearin g
preload . Th e tota l bearin g preloa d shoul d excee d
th e driv e pinio n bearin g preloa d b y th e amoun t
show n i n th e nex t column .
NOTE : Rotat e th e driv e pinio n severa l time s t o
ensur e prope r bearin g contact .
=0.94 -1.0 7 N- m (9. 6 -10. 9 kgf-cm , 8.3 3 - 9.4 6 Ibf-in )
If th e tota l bearin g preloa d i s no t withi n th e standard ,
correc t i t b y increasin g o r decreasin g th e preloa d o n th e
carrie r bearing s a s needed . I f ther e is to o muc h preload ,
decreas e th e shi m thicknes s equa l amount s o n bot h
sides . I f ther e i s no t enoug h preload , increas e th e shi m
thicknes s equa l amount s o n bot h sides .
NOTE : B e sur e th e sam e amoun t o f shi m thicknes s i s
adde d o r subtracte d fro m bot h sides , s o tha t th e toot h
contac t patter n an d backlas h ar e no t affected .
24 . Instal l th e oi l sea l usin g th e specia l tool s a s shown .
NOTE: Mak e sur e tha t distanc e i s correct .
DRIVER07749-001000 0
PINION COVE R DRIVE RATTACHMEN T07LAD-PW5050 0
15.5-16.0 m m(0.6 1 - 0.63 in)
OIL SEA L
Replace .
PROCES S SURFAC E
BAS E SURFAC E
PROCESS SURFAC E
= 1.0 4 -1.2 6 N- m (10. 6 -12. 8 kgf-cm , 9. 2 -11. 1 Ibf-in )
Reuse d differentia l carrie r tapere d rolle r bearing :
Tota l bearin g preloa d (fro m ste p 23 )
- T p (fro m ste p 18 )
Standard
:
Ne w differentia l carrie r tapere d rolle r bearing :
Tota l bearin g preloa d (fro m ste p 23 )
-Tp (fro m ste p 18 )
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Driveshafts
Removal
1. Loose n th e whee l nut s slightly .
2 . Rais e th e fron t o f th e vehicle , an d suppor t i t wit h
safet y stand s in th e prope r location s (se e sectio n 1 ).
3 . Remov e th e whee l nut s an d fron t wheels .
WHEEL NU T12 x 1. 5 m m
SPINDL E NU T24 x 1. 5 m mReplace . FRON
T WHEE L
4. Drai n th e differentia l oi l (se e sectio n 15 ).
NOTE : I t i s no t necessar y t o drai n th e differentia l oi l
whe n th e lef t driveshaf t i s removed .
5. Rais e th e lockin g ta b o n th e spindl e nut , the n remov e
the nut .
6. Remov e th e self-lockin g nu t an d flang e bolt s fro m
th e dampe r fork .
DAMPE R FOR K
Chec k fo r damage . FLANG
E BOL T
10 x 1.2 5 mm
7. Remov e th e dampe r fork .
SELF-LOCKIN G NU T12 x 1.2 5 mmReplace .
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Reassembly (cont'd )
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 i n th e
ste p - "C " fro m th e tota l thicknes s o f th e fou r shims .
(Tota l thicknes s o f th e fou r 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 .
55 . Se t th e selecte d 4 4 m m shim s o n th e bearin g surfac e
o f th e gearbo x housing . 60
. 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 .
Power Steerin g Gearbo x
61. Greas e th e slidin g surfac e of the rac k guide , an d
instal l i t ont o th e gearbo x housing .
62 . Fo r '9 6 - 9 8 models : Appl y a thi n coa t o f greas e t o
th e ne w 0-ring , an d instal l i t o n th e rac k guid e screw .
Fo r '9 9 - 0 1 models : Appl y sealan t t o th e al l aroun d
thread s o n th e rac k guid e screw .
63 . Instal l th e spring , rac k guid e scre w an d locknu t o n
th e gearbo x housing .
64 . Adjus t th e rac k guid e scre w (se e pag e 17-16 ).
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 .
56
. 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 .
57 . Appl y greas e t o th e needl e bearin g i n th e gearbo x
housing .
58 . 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 positio n
(directio n o f lin e connection) .
59 . Tighte n th e flang e bolt s t o th e specifie d torque .
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65. Install the new lock washer in the groove in the

steering rack.

66. Install the steering rack ends into the rack.

67. Hold the steering rack with a wrench ('99 - 01 mod-

els: left end only), and tighten the rack ends with

another wrench.
69. Apply steering grease to the circumference of the

rack end housing.

70. Apply a light coat of silicone grease to the boot

grooves on the rack ends.

71. Install the boots in the rack end with the tube clamps.

NOTE: Install the boots with the rack in the straight

ahead position (right and left tie-rods are equal in

length).
68. After tightening the rack ends, stake the four section

of lock washer with a commercially-available roll

pin drift and mallet.

• Place the wood block, then set the lock washer

section of rack end securely on the wood block.

• Be sure the tool is aligned with the stake point

(four dents) of the steering rack end before stak-

ing.ProCarManuals.com

75. 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 . 78
. 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 .
73
. Ben d bot h set s o f lockin g tabs .
74 . Lightl y ta p o n th e doubled-ove r portion s t o reduc e
thei r height .
CAUTION : Stak e th e ban d lockin g tab s firmly . 76
. Instal l th e thre e line s ( 6 m m retur n line , 1 0 m m
retur n lin e an d senso r inle t line ) t o th e valv e bod y
uni t a s shown .
77 . Instal l th e lin e mountin g cushion s b y alignin g th e
mark s o n th e 1 0 m m retur n lin e (larg e diamete r
line).
Reassembl y (cont'd )
72. Instal l th e ne w boo t band s o n th e boot s a s shown .
Power Steerin g Gearbo x
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1. Loose n th e whee l nut s slightly .
2. Rais e th e fron t o f th e vehicle , an d suppor t i t wit h
safet y stand s in th e prope r location s (se e sectio n 1 ).
3 . Remov e th e whee l nut s an d fron t wheel .
WHEE L NU T108 N- m(11 kgf-m , 8 0 Ibf-ft )
SPINDL E NU T 2 4 x 1. 5 m m245 N- m(25 kgf-m , 18 1 Ibf-ft )Replace .NOTE:• Befor e installin g th e spindl e nut , appl y
engin e oi l t o th e seatin g surfac e o f th e nut .
• Afte r tightening , us e a drif t t o stak e th e
spindl e shoulde r agains t th e spindle .
4. Rais e th e lockin g ta b o n th e spindl e nut , the n
remov e th e nut .
5 . Remov e th e brak e hos e mountin g bolts .
BRAK E HOS E
9.8 N- m(1.0 kgf-m , 7. 2 Ibf-ft )22 N- m(2.2 kgf-m , 1 6 Ibf-ft )
6. Remov e th e whee l senso r fro m th e knuckle .
NOTE : D o no t disconnec t th e whee l senso r connec -
tor.
9.8 N- m (1. 0 kgf-m , 7. 2 Ibf-ft )
SENSO R MOUNTIN GBOLTS9.8 N- m(1.0 kgf-m , 7. 2 Ibf-ft )
WHEE L SENSO R
7. Remov e th e calipe r bracke t mountin g bolts , an d
han g th e calipe r assembl y t o on e side .
CAUTION : T o preven t accidenta l damag e t o th e
calipe r o r brak e hose , us e a shor t piec e o f wir e t o
han g th e calipe r fro m th e undercarriage .
CALIPER BRACKE T MOUNTIN G BOLT S12 x 1.2 5 mm108 N- m (1 1 kgf-m , 8 0 Ibf-ft )
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Rear Dampe r
Do no t damag e th eslidin g surfac e o fthe bal l pi n wit hthe bearin g puller .
RETAINE R(Upper bal l join tonly)
BAL L PI N TAPERE D SECTIO N
4. Wip e th e greas e of f th e slidin g surfac e o f th e bal l
pin , pac k i t wit h fres h grease , an d instal l th e retaine r
(Uppe r bal l join t only) .
CAUTION :
• Kee p greas e of f th e boo t installatio n sectio n an d
th e tapere d sectio n o f th e bal l pin .
• D o no t allo w dust , dirt , o r othe r foreig n materi -
als to ente r th e boot .
5 . Instal l th e boo t i n th e groov e o f th e boo t installatio n
sectio n securely , the n blee d air .
6 . Adjus t th e specia l too l wit h th e adjustin g bol t unti l th e
en d o f th e too l align s wit h th e groov e o n th e boot .
Slid e th e se t rin g ove r th e too l an d int o position .
BALL JOIN T BOO T
CLI P GUID E
07GA G - SD4070 0 ADJUSTIN
G BOL TAdjust th e dept h b yturnin g th e bolt .
SET RIN G
BOO T
CAUTION : Afte r installin g th e boot , chec k th e bal l
pi n tapere d sectio n fo r greas e contamination , an d
wip e it i f necessary .
Removal
1. Rais e th e rea r o f th e vehicle , an d suppor t i t wit h
safet y stand s in th e prope r location s (se e sectio n 1 ).
2 . Remov e th e rea r speake r an d dampe r cap .
DAMPE R CA P
DAMPER MOUNTIN G NUT S10 x 1.2 5 mm
3. Us e a floo r jac k t o compres s th e dampe r slightly .
4 . Remov e th e dampe r mountin g nuts .
5 . Remov e th e dampe r mountin g bolt .
DAMPE RMOUNTIN G BOL T
6. Lowe r th e rea r suspension , an d remov e th e dampe r
assembly .
NOTE : Mar k th e righ t an d lef t damper s o r stor e
the m separatel y s o the y can be reinstalle d o n th e
prope r sides .
SET RIN G
BOO T
Ball Join t Boo t Replacemen t
1. Remov e th e se t rin g an d th e boot .
2 . Remov e th e retaine r (uppe r bal l join t only) .
CAUTION : D o no t contaminat e th e boo t installa -
tio n sectio n wit h grease .
3 . Pac k th e interio r o f th e boo t an d li p wit h grease .
Replace a s aset .
BEARIN GPULLER
Rear Suspension
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Inspection and Adjustment

Brake Pedal

Pedal Height

1. Disconnect the brake pedal position switch connec-

tor, loosen the brake pedal position switch locknut,

and back off the brake pedal position switch

until it is no longer touching the brake pedal.

2.

Lift up the carpet. At the insulator cutout, measure

the pedal height from the middle of the right side of

the pedal pad.

PUSHROD

LOCKNUT
BRAKE PEDAL POSITION SWITCH

BRAKE PEDAL POSITION SWITCH

LOCKNUT

INSULATOR

(CUTOUT)

MEASURING POINT

Standard Pedal Height (with carpet removed):

182 mm (7
3/16
in)

3. Loosen the pushrod locknut, and screw the pushrod

in or out with pliers until the standard pedal height

from the floor is reached. After adjustment, tighten

the locknut firmly.

NOTE: Do not adjust the pedal height with the

pushrod pressed.

Lower the pedal

PUSHROD LOCKNUT

15 N-m

(1.5 kgf-m, 11 Ibf-ft)
4.
Screw in the brake pedal position switch until its

plunger is fully pressed (threaded end touching the

pad on the pedal arm). Then back off the switch 1/4

turn to make 0.3 mm (0.01 in) of clearance between

the threaded end and pad. Tighten the locknut firm-

ly. Connect the brake pedal position switch connec-

tor.

CAUTION: Make sure the brake lights go off when

the pedal is released.

PAD

5. Check the brake pedal free play as described below.

Pedal Free Play

1. With the engine off, check the play on the pedal pad

by pushing the pedal by hand.

Free Play: 0.5 - 2.0 mm (0.02 - 0.08 in)

2. If the pedal free play is out of specification, adjust

the brake pedal position switch.

CAUTION: If the pedal free play is insufficient, it

may result in brake drag.

BRAKE PEDAL POSITION SWITCH

BRAKE PEDAL PAD

PEDAL FREE PLAY
LOCKNUT
THREADED

END

0.3 mm

(0.01
in)
BRAKE PEDAL PAD

PEDAL HEIGHT

Raise

the pedalProCarManuals.com