Overhaul

Before disassembling the steering gear, clean gear thoroughly to prevent dirt from entering the unit. During disassembly, carefully note and label disassembled component (part) from the main gear unit to aid in the assemble process.

Fig. 6 Power steering gear exploded view. Civic:

Control Unit Disassembly

1. Drain power steering fluid, then remove pressure lines using suitable wrench.
2. Remove valve body attaching bolts to steering gear housing, Fig. 6.

Fig. 7 Port orifice removal. Civic w/power steering:

3. Remove O-rings and port orifices from gear housing, Fig. 7.
4. Remove O-ring from valve body.
5. Remove pinion dust seal from valve body.
6. Remove valve port attaching bolts, then valve port from valve body.
7. Remove port seal.
8. Remove cut-off valve and spring from body, then separate valve body from housing.
9. Remove cap seals and dowel pins from valve body.
10. Remove control valve rollers from valve body.
11. Remove plungers, return springs and reaction control valve, then seal from control valve.
12. Reverse procedure to assemble, noting the following:
a. Thoroughly clean disassembled parts prior to assembly.
b. Replace all O-rings and seals.
c. Coat plungers, control valve and cut-off valve with power steering fluid.

Steering Gear Disassembly

1. With steering gear removed from vehicle, remove control unit. Refer to ``Control Unit Disassembly.''
2. Remove boots and bands.
3. Straighten tie rod lock washers, then remove tie rods using 19 mm and 17 mm wrench. To prevent damage to sealing surface of steering rack, push rack into cylinder.
4. Remove rack locknut, guide screw, spring and rack guide.
5. Remove housing cap attaching bolts, then cap and O-ring.
6. Remove 32 mm snap ring from gear housing.
7. Remove pinion from gear housing.
8. Remove 15 mm snap ring and bearing from pinion.
9. Remove cylinder housing attaching bolts, then cylinder, rack bushing A and cylinder spring.
10. Remove cylinder end seal from cylinder.
11. Remove cylinder barrel, seal retainer, cylinder cap and rack from gear housing.
12. Remove retainer washer and 46.5 mm O-ring from gear housing.
13. Remove the 31 mm snap ring, then pinion holder from gear housing.
14. Remove bearing from housing.
15. Inspect pinion bearings and replace if worn or damaged.
16. Install pinion holder in housing, then 31 mm snap ring with taper side facing out.
17. Remove cylinder barrel and seal retainer from steering rack.
18. Remove the 24.9 mm O-ring, ring stopper on 1985-86 models, or circlip on except 1985-86 models, and cylinder cap from seal retainer, then two 33.5 mm O-rings from cylinder cap.
19. Remove rack bushing B from seal retainer, then cylinder end seal.
20. Carefully remove piston seal ring using a suitable screwdriver, then the 27.5 mm O-ring.
21. Prior to assembly, clean all disassembled parts, replace all O-rings and seals.
22. Install 27.5 mm O-ring in rack groove, then piston seal ring using suitable tool.
23. Coat piston seal ring and sizing tool 07974-SA50200 or equivalent, with power steering fluid. Slide tool onto rack and over piston seal ring, then rotate tool to break in piston ring.
24. Install both 33.5 mm O-rings on cylinder cap, then slide cylinder cap onto seal retainer.
25. Install ring stopper or circlip and 24.9 mm O-ring on seal retainer.
26. Install rack bushing B with groove facing steering rack piston.
27. Coat end seal slider tool 07974-SA50300 or equivalent and cylinder end seal with a suitable grease, then install end seal on slider tool with groove toward tool.

Fig. 8 Rack installation. Civic w/power steering:

28. Coat rack and teeth with a suitable grease, then install tool on steering rack. Face rack teeth away from slider tool slot, Fig. 8.
29. Remove slider tool, then install seal retainer on steering rack.
30. Push rack bushing B into seal retainer.
31. Install the 46.5 mm O-ring and retainer washer into gear housing.
32. Place gear housing in a suitable vise and press seal retainer and steering rack into gear housing.
33. Coat cylinder barrel with power steering fluid and slide barrel over rack into gear housing until it seats.
34. Place end seal guide tool 07974-SA50400 or equivalent onto steering rack, then install cylinder spring over rack.
35. Coat rack bushing A with power steering fluid and install it on cylinder spring.
36. Coat inside of cylinder with power steering fluid and install cylinder end seal with groove facing in.
37. Coat end seal guide tool 07974-SA50400 or equivalent with a suitable grease, then slide cylinder over rack onto gear housing.
38. Push steering rack into cylinder to prevent damage to steering rack.
39. Torque cylinder bolts to gear housing to 16 ft. lbs.
40. Using a suitable press, install bearing on pinion with seal side facing down.
41. Install the 15 mm snap ring on pinion, then check that pinion bearing turns smoothly.
42. Install pinion assembly into pinion holder in gear housing.
43. Install 32 mm snap ring in groove in pinion, with taper side facing out.
44. Coat the 44 mm O-ring with a suitable grease and install it in groove in housing cap.
45. Torque housing cap attaching bolts to 9 ft. lbs. Arrow on housing cap must face toward front of car when gear box is installed.
46. Coat rack guide with a suitable grease, then install rack guide, spring, O-ring and rack guide screw into gear housing.
47. Install locknut on rack guide screw finger tight.
48. Tighten guide screw until it seats against guide, then loosen it. Torque guide screw to 3 ft. lbs. and back off 1/10 of a turn.
49. While holding guide screw, torque locknut to 18 ft. lbs.
50. Install tie rod, torque to 42 ft. lbs., then bend lock washers against flat on flange.
51. Install boots and bands.