1999 HONDA CR-V ect

28. Using a cutte. or an equivalent tool, cut and remove
the four seal rings from the sleeve. Be careful not to
damage the edges ot the sleeve grooves and outer
surface when removing the seal rings.
Using a cutter or an equivalent tool. cut the valve
seal ring and O-ring at the groove in the pinion
shaft. Remove the valve seal ring and O-ring. Be
careful not to damage the edges of the pinion shaft
groove and outer surface when removing the valve
seal rjng and O-ring.
29.
SLEEVE
Cufting slot position.
30. Remove the valve oil seal and backup ring ('97
model) or wave washer ('98 - 00 models) from the
pinion shaft.
Note these items during disassembly:
. Inspect the ball bearing by rotating the outer race
slowly. lf there is any 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 Dinion shafts and
sreeves,
WAVE WASHERl'98 - 0O modelsl
PINION SHAFT
BACKUP RING{'97 modellVALVE OIL SEAL
31.Replace.Press the valve oil seal and roller bearing out of the
valve housing using a hydraulic press and special
tool shown below.
BALL BEARING
PILOT COLLAR
ROLLER SEARING
www.emanualpro.com

Power Steering Gearbox
13.
Reassembly (cont'd)
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. Install two rings at a time
Jrom each end ofthe sleeve.
Note these items when installing the seal ring:
. 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. Do not mix the different types of
sleeve seal rings as they are not compatible.
Align the special tool with each groove in the sleeve,
and slide a sleeve seal ring into each groove. After
installation, compress the seal rings with your fin-
gers temporarily.
BALL JOINT BOOT CLIP GUIDE07974 - SA508q)
SLEEVE
Apply power steering fluid to the seal rings on the
sleeve, and to the ehtire inside surface of the special
tool.
14.
15.
SLEEVE SEAL RINGSIZING TOOL07974 - SA502O0 or07974 - SA5020A
16.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. Be sure
that the seal rings are not turned up,
't1.
18. Apply power steering fluid to the surface of the pin-
ion shaft. Assemble the sleeve over the Dinion 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 these items during reassembly:
. Be caretul not to damage the valve seal ring
when inserting the sleeve.
. Install the circlip with its radiused side facing out.
Apply power steering fluid to the seal ring lip of the
valve oil seal. then install the seal in the valve hous-
ing using a hydraulic press and special tools. Install
the valve oil seal with its grooved side facing the tool.
19.
ATTACHMENT,32x35mm077i16 - (x)10100
VALVE OIL SEALReplace.Make sure thespring is in theoilseal.
CIRCLIP
www.emanualpro.com

Power Steering Gearbox
Reassembly (cont'dl
4l. Coat the inside surface of the new cvlinder end seal
with power steering fluid.
CYLINDEB ENO SEALReplace.Make sure the springis in the cylinder end seal.
43.
Stakedposrtron.
Grooved side.
42. Install the cylinder end seal onto the steering rack
with its grooved side toward the piston.
Push in the cylinder end seal with your finger.
When installing the cylinder end seal, be careful not
damage the sealing face of the seal with the threads
and burrs at the staked position of the cylinder
housing.
Remove the vinyl tape from the steering rack, then
remove any residue from the tape adhesive.
Hold the gearbox using a C-clamp as shown.
GEARBOX
44.
45.
C.CLAMP
17-46
46.Grease the inside surtace of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der.
Remove the C-clamp from the gearbox.
After tightening the cylinder end, stake the point of
the cylinder shown below. Stake the cylinder in the
position opposite from where the stake was removed
during disassembly,
NOTE: For '98 - 00 models, go to step 54.
41.
48.
BUSHING
-tGCYLINDER END69 N.m (7.0 kgf.m,51 lbtft)8e careful not to damagethe bushing when insertingthe cylinder end.
49. Select the 32 mm shim(s) ('97 model onlv).
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-
lows.
Shim selection:
Set the four 32 mm shims on the bearing surface of the
gearbox housing. Total thickness of the four shims
should equal no more than 0.70 mm.
Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15
mm, 0.20 mm, 0.25 mm respectively)
NOTE: The four 32 mm shims do not have thickness
identification marks. Measure the thickness of each shim
using a micrometer, and mark the shim for identification.
Stake point, Depth: 1,0 mm (0.04 inl
4.0 mm {0.16 in)
www.emanualpro.com

50. Install the valve body unit on the gearbox. and
tighten the flange bolts to the specified torque.
VALVE BODYFLANGE BOLT20 N.m 12.0 kgt.m, 14lbtft)
ct.
SHIM SET(four shims)
Measure the clearance between the gearbox and
valve body unit using a feeler gauge. Measure the
clearance at the poinl midway between the two
mounting bolts.
GAUGE
Determine the required thickness of the 32 mm
shims by subtracting the clearance obtained in the
step "c" from the total thickness of the four shims.
(Total thickness of the 4 shims) - (Clearance) =
Reouired thickness of the shims
Select the shims so that the total thickness is close
to, but less than, the required thickness.
Example:
Measurement is 0.28 mm (0.011 in);
0.70-0.28=0.42 mm (0.028-0.011 = 0.017 in)
The selected shims should be 0,25 mm (0.010 inl and
0.15 mm (0.006 in) in thickness.
lf the required shim thickness is 0.10 mm or less, no
shrms are necessary.
53. Set the selected 32 mm shims on the bearing sur-
face of the gearbox housing.
VALVE BODY UNITla lbl.frl
Coat the new O-ring with grease, and carefully fit it
on the valve 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 the valve body unit
installation position (direction of line connection).
Tighten the flange bolts to the specified torque.
(cont'd)
FLANGE BOLT20 N.m (2.0 kgf.m,
/a)E?
E
O.RINGReplace.
-6{
NEEDLE BEARING
-6lr
54.
56.
57.
17-47
www.emanualpro.com

Power Steering Gearbox
Reassembly (cont'dl
58. Installthe cylinder lines A and B
Note these items during reassembly:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by hand first, then tighten the flare
nuts to the soecified torque.
CYLINDEF LINE A
Grease the sliding surface of the rack guide, and
install it onto the gear housing.
For'97 model, apply a thin coat of grease to the new
O-ring, and install it on the rack guide screw.
For'98 - 00 models. remove the old sealant from
the threads of the rack guide screw. then apply new
sealant to the first three threads.
-6rO-RING
nlcr cutDE R"Pl""u'
SCREW
LOCKNUT
37 model:
60.
ot.
38 model:
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17,15). After
adjusting, check that the rack moves smoothly by
sliding the rack right and left.
17 N.m 11.7 kgd.m, 12lbf.ttl
26 N.m {2.7 kgl.m, 20
RACK GUIOE
17-48
STEERING RACK
(
63. Install the new lockwasher in the groove in the
steering rack.
LOCK WASHERReplace.
STEERING RACK ENO54 N.m (5.5 kgf.m,40 lbtftl
64.
STEERING
Screw the rack ends into the rack.
Hold the steering rack with a wrench ('98 - 00 mod-
els: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
wrench.
After tightening the rack ends, stake the four sec-
tions of lock washerwith a drift and a mallet.
. Place the wood block on the press table, then set
the lock washer section of the rack end on the
wood block securely.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing.
. Stake the lock washer in the center of the flat
section of the steering rack end,
ROLL PIN PUNCH
lCommorcially.Y.il.blelSnap-On No. PPR8 or oquival.nt.
NOTE: This drift has a flatshoulderto preventpuncturing of metal washer.
WOODEN BLOCK
www.emanualpro.com

67. Apply grease to the circumference of the rack end
housing.
68.
69.
RACK END GROOVE
.={@
SILICONE GREASE
Apply a light coat of silicone grease to the boot
grooves on the rack ends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boots with the rack in the straight
ahead position (right and left tie-rods are equal in
length).
RACK ENO
NOTE: Wipe the grease offthe thread section.
TIE.ROD CLIP
17-49
70. Adiust the air hose fitting position of the boots by
turning it as shown below.
LEFT BOOT{Viewed from theleft side)
+rom
''rT.a'.
, tri"
\,'tAr-
{,1@}tr
)Fr1
/\
RIGHT BOOT(Viewed trom theright side)
Front
+
BOOT AIR HOSE FITTING
71. Install new boot bands on the boot, and bend both
sets of locking tabs.
CAUTION: Stake the band locking tabs firmly.
Lightly tap on the doubled-over portions to reduce
their height.
Slide the rack right and left to be cenain that the
boots are not deformed or twisted.
(cont'd)
FIT'I'ING
www.emanualpro.com

Power Steering Gearbox
Reassembly (cont'd)
74. Connect the air tube between the right and left
boot,
CYLINDERLINE A
75. Install the clips on the cylinder lines, then clamp theair tube with the clips.
76. Apply vinyl tape to around the pinion shaft, andcoat the surface of the tape with grease.
DUST COVER
Vinyl Tsp€
VALVE OIL SEAL
VALVE BODY UNIT
Pack the interior of the dust cover and lio withgrease, then install dust cover on the valve bodv unit.
Remove the vinyl tape f.om the pinion shaft.
77.
CYLINDER LINE
17-50
SET RING
't.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot inslalla-
tion section with graase.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ballpin. then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation section and
the tapered section of th€ ball pin.
. Do not allow dust, dirt, or other to.eign materi-
als to enter the boot.
EALL PIN TAPEREDSECTIONWipe olf the grease.
BOOT INSTALLATIONSECTIONWipe offthe grease.
B(X)T IT{STALLATIONsEclroNWipe off the grease.
ADJUSTING BOLTAdiust the depthby turning the bolt.
Install the boot in the groove of the boot installation
section securely. then bleed air.
Adjust the special tool with the adjusting bott untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
I|on.
CAUTION: After installing the boot, chock the batlpin lapered section for grease contamination andwipe it it n€cessary.
www.emanualpro.com

Power Steering Gearbox
Installation (cont'd)
8, Install the left front mount. Tighten the mountingbolts in order: A and B.
LEFT FRONT MOUNT
B-12 x 1,25 mm59Nm(6.0 kgtm,,€ lbl.ftlReplaca.
9. Instsll the right front mount, Tighten the mountingbolts in order: A and B.
B-12 x 1.25 mm59 N.m16.0 ks[.m, ,|:| lbf.ftlReplace.
A-10 x 1.25 mm4,1 N.mla.s kgt m, 33 lbf.ft)
A-10 x 1.25 mma,a N.m
10. Remove the vinyl type from the side frame (both
sides).
17-52
11. Installthe return hose joint by tightening the 16 mmflare nut.
AD.'USTAB[T HOSE CLAMP(For installationreter to page 17,23)
RETURN HOSE JOINT:16 mm FLARE NUT28 N.m12.9 kg{.m.21 lbt{t)
14 mm FLARE NUT37 N.m(3.8 ksf.m, 27 lbl'frl
't2.
13.
Connect the return hose securely. and tighten theadjustable hose clamp.
Connect the pump outlet hose, and tighten the l4mm flare nut.
NOTE: Make sure that there is no interferencebetween the fluid lines, the rear beam or any otherparts.
www.emanualpro.com