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.

Control Unit Disassembly

1. Drain power steering fluid, then remove gear box shield.
2. Remove pressure lines using suitable wrench.

Fig. 2 Power steering gear exploded view. Prelude & 1984-85 Accord:

3. Remove control unit attaching bolts to steering gear housing, Fig. 2.

Fig. 3 Typical power steering control unit removal:

4. Remove orifice A and B with O-rings, Fig. 3.
5. Remove valve body cap attaching bolts, then valve body cap.
6. Remove O-ring and cap seal from valve body cap.
7. Remove cut-off valve and spring from body, then separate valve body from housing.
8. Remove valve port housing dowel pins and seal.
9. Remove control valve O-ring, then inspect cut-off valve for scoring and scratches. If valve body is damaged, replace all three parts as a unit.
10. Remove control valve rollers from valve body.
11. Reverse procedure to assemble, noting the following:
a. Clean all 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 boot bands, then boots. Straighten tie rod locks, then remove tie rods using two 19 mm wrenches.
3. Push right end of cylinder rack into housing.
4. Remove rack locknut and guide screw, then the 32 mm snap ring securing pinion lower ball bearing.
5. Remove pinion from gear housing.
6. Remove 15 mm snap ring, then separate lower ball bearing and pinion.
7. Remove cylinder housing attaching bolts, then slide housing off rack.
8. Remove rack bushing, cylinder spring and cylinder end seal from cylinder.
9. Remove cylinder seal retainer, cap and steering rack from gear housing.
10. Remove retainer washer and 46.5 mm O-ring from gear housing.
11. Remove pinion dust seal retainer bolts, dust seal and retainer.
12. Inspect pinion upper bearing. Replace if worn or damaged.
13. Remove cylinder and seal retainer from rack.
14. Remove two 35 mm O-rings from cylinder cap.
15. Remove 24.5 mm O-ring and snap ring from seal retainer, then slide off cylinder cap.
16. Remove cylinder end seal from retainer, then remove rack piston ring and 27.5 mm O-ring.
17. Prior to assembly, clean all disassembled parts, replace all O-rings and seals.
18. Install 27.5 mm O-ring in rack groove, then piston ring using suitable tool.
19. Install both 33.5 mm O-rings on cylinder cap, then slide cylinder cap onto seal retainer.
20. Install 28 mm snap ring and 24.5 mm O-ring on seal retainer.
21. Grease sliding surface of cylinder end seal (white), then install seal in seal retainer. Both cylinder end seals are the same size, but are not interchangeable. The white seal goes in end of retainer and black seal goes in end of cylinder housing.
22. Install 46.5 mm O-ring and retainer washer into gear housing.
23. Press seal retainer into gear housing, then stand housing on suitable workbench.

Fig. 4 Steering rack installation. Prelude (except models with 4 wheel steering) & 1984-85 Accord w/power steering:

24. Install cylinder end seal slider tool, then install rack in seal retainer. Face rack teeth away from end seal slider tool slot, Fig. 4.
25. Remove slider tool, then install cylinder over rack until it seats in housing. Coat rack and inside of cylinder with power steering fluid to help prevent damaging O-ring.
26. Install cylinder spring, then rack bushing.
27. Install cylinder seal (black) using suitable tool.
28. Install cylinder to gear housing attaching bolts. Torque bolts to 7 ft. lbs.
29. Press lower bearing on pinion, using suitable press.
30. Install pinion snap ring, then pinion and holder in gear housing.
31. Install snap ring in pinion holder from underside of gear housing.
32. Install seal, retainer and 46 mm O-ring in seal retainer.
33. Install dust seal on pinion using suitable tool.
34. Install retainer to housing attaching bolts.
35. Install control unit. Refer to ``Control Unit Disassembly.''
36. Install rack guide, spring, rack guide screw and locknut. To adjust, refer to ``Front Suspension & Steering.''

Fig. 5 Typical tie rod installation:

37. Install tie rod, torque to 54 ft. lbs. on Accord or 40 ft. lbs. on Prelude models, then bend lock washer against flat on flange, Fig. 5.
38. Install boots, mounts and steering gear.
39. Install shift rod torque arm and torque to 9 ft. lbs.
40. On vehicles with 5 speed transmissions, install rod and torque clevis bolts to 16 ft. lbs.
41. Install pressure lines, then center beam, torquing bolts to 16 ft. lbs.
42. Install tie rod to steering knuckle, torque castle nuts to 32 ft. lbs., then install cotter pins.
43. Install steering shaft connector, then fill reservoir with fluid, start engine and check for leaks.
44. Install shield, then front wheels.