Steering Gearbox Removal and Installation

Steering Gearbox Removal and Installation
Special Tools Required
^ Ball joint remover, 28 mm 07MAC-SL0A202
^ Subframe adapter EQS02C000016
*Available through the Honda Tool and Equipment program 888-424-6857

Removal
Note these items during removal:
^ Using solvent and a brush to wash any oil and dirt off the end of the gearbox. Avoid any electrical parts. Blow dry with compressed air.
^ Make sure to remove the steering wheel before disconnecting the steering joint to avoid damaging the cable reel.

1. Make sure you have the anti-theft codes for the radio and the navigation system (if equipped), then write down the XM radio channel presets.
2. Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
3. Raise the front of vehicle, and support it with safety stands in the proper locations.
4. Remove the front wheels.
5. Remove the steering wheel.
6. Remove the driver's under cover.





7. Remove the steering joint cover A.





8. Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column. Hold the slider shaft (C) on the column with a piece of wire (D) between the joint yoke (E) on the slider shaft to the joint yoke on the upper shaft.





9. Remove the center guide (A), and discard it.
10. Remove the steering joint cover B. Be careful not to damage the mating surface on the joint cover B and pinion shaft grommet.





11. Remove and discard the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut.
12. Separate the tie-rod ball joint and knuckle using the special tool.





13. Remove the splash shield (A).





14. Disconnect the torque sensor 3P connector (A) from the steering gearbox.





15. Disconnect the motor 2P connector (A) and the ground terminal (B) from passenger's side of the steering gearbox, and wrap the connectors with vinyl tape to avoid the contamination from grease or water.
16. Remove the connector (C) pushing the tab (D) from the connector stay (E).

NOTE: Do not disconnect the connector.

17. Remove the ground male terminal (F) and the connector stay.





18. Remove the self-locking nuts (A) on the under-floor three-way catalytic converter (TWC) (B).

NOTE: Use new self-locking nuts on reassembly.





19. Remove the self-locking nuts (B) on the front of the exhaust pipe A.

NOTE: Use new self-locking nuts on reassembly.





20. Remove the exhaust pipe A mount (B), then remove the exhaust pipe A with the TWC.





21. Remove the P/S heat baffle plate (A).





22. Remove the transmission lower mount bolts (A).





23. Remove the subframe rear damper (A), and rear engine mount base mounting bolts (B).





24. Remove the steering gearbox mounting bolts (A) on driver's side of the gearbox, and remove the mounting bracket (B).





25. Remove the steering gearbox mounting bolts (A) from the passenger's side of the gearbox, then remove the gearbox mounting bracket (B) and cushion (C).





26. Attach the front subframe adapter to the subframe (A) by hanging the belt (B) over the front of the subframe, then install the lockpin (C) and tighten the wingnut (D).
27. Raise the jack (E) and line up the slots in the arms with the bolt holes on the corner of the jack base, then attach them with bolts securely.





28. Support the engine and the transmission with the jack stand (A).





29. Remove the subframe right middle mounting bolts (A).





30. Remove the subframe left middle mounting (A).





31. Remove the subframe front bracket (A) mounting bolts (B), and loosen the flange bolts (C) about 15 mm (9/16 inch) from the mounting surface on both sides of the vehicle.





32. Remove the subframe rear bracket (A) on the right and left of the vehicle from the subframe.





33. Slowly, lower the jack supporting the subframe (A) with the special tool until the subframe has dropped about 50 mm (1 15/16 inch).





34. Move the steering gearbox toward the front, and remove the pinion shaft grommet (A) from the top of the torque sensor (B).
35. Apply vinyl tape (C) to the splines on the pinion shaft.





36. Move the steering gearbox to the driver's side, and rotate it so the pinion shaft (A) points toward the front of the vehicle.





37. Carefully move the steering gearbox (A) as an assembly toward the driver's side of the vehicle until the pinion shaft clears the wheelwell opening. Be careful not to damage the brake lines with the pinion shaft.
38. Remove the gearbox through the wheelwell opening on the driver's side.
Be careful not to damage these parts due to interference with the edge of the wheelwell opening when extracting and inserting the steering gearbox.
^ Torque sensor housing
^ Boots
^ Serrations of the pinion shaft
^ Motor 2P connector
^ Tie-rod end ball joint boots

Installation
1. Before installing the steering gearbox, make sure that no fluid or grease is on the mating surface of the gearbox and the front subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove the fluid or grease from the mount cushions and bolt holes.





2. Apply a mild soap and water solution to both sides of the mount cushion mating surfaces (A).
3. Pass the motor (B) of the steering gearbox through the wheelwell opening on the driver's side.
4. Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheelwell opening on the body.





5. Rotate the steering gearbox so the pinion shaft (A) points upward.
6. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. Make sure the torque sensor 3P connector and motor 2P connector are routed above the gearbox.





7. Remove the vinyl tape from pinion shaft, and install the pinion shaft grommet (A). Align the slots in the pinion shaft grommet with the lug portions (B) on the torque sensor housing.
8. Raise the jack supporting the front subframe with the special tool until the subframe is in position.





9. Install the subframe rear bracket (A). Tighten the 12 mm flange bolts (B) and 14 mm bolts (C) to the specified torque on the both sides of the vehicle.





10. Install the subframe front bracket (A) with the bracket mounting bolts (B), then tighten the flange bolts (C) to the specified torque on both sides of the vehicle.





11. Install the subframe left mid mount (A).





12. Install the subframe right mid mount bolts (A).





13. Loosely install the mounting bracket (A) and gearbox mounting bolts on the driver's side of the gearbox.





14. Position the cutout (A) on the mounting cushion (B) as shown, and install it on the passenger's side of the gearbox securely.
15. Install the gearbox mounting bracket (C) over the mounting cushion.
16. Tighten the flange bolts on both sides of the gearbox to the specified torque alternately in two or more steps.





17. Install the rear engine mount base mounting bolts and subframe rear damper (A).





18. Install the transmission lower mount (A).
19. Lower the jack stand, and tighten the mounting bolts to the specified torque.





20. Install the P/S heat baffle plate (A).





21. Install the exhaust pipe A mount (B), with the exhaust pipe A and the three way catalytic converter (TWC).





22. Install the new the self-locking nuts (B) on the front of the exhaust pipe A.





23. Install the new self-locking nuts (A) on the under floor the three-way catalytic converter (TWC) (B).





24. Install the connector stay (A) and the ground male terminal (B) to the steering gearbox, and install the connector (C) to the connector stay.
25. Remove the vinyl tape, then connect the motor 2P connector (D) and ground terminal (E) to the steering gearbox. Make sure to push the motor 2P connector until you hear a click so that the connector is secured.





26. Connect the torque sensor 3P connector (A) to the steering gearbox. Make sure to push the connector until you hear a click so that the connector is secured.





27. Install the splash shield (A).





28. Wipe off any grease from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms,
29. Install the tie-rod end ball joint nut, and tighten it to the specified torque. Then install the new cotter pin (B), and bend it as shown (C) or (D).





30. Install the new cover seal (A) all the way around in the steering joint cover B. Make sure there are no wrinkles in the seal, then install the steering joint cover B.
31. Center the steering rack within its stroke.





32. Position the steering column joint (A) so the bolt (B) near to the notch (C) is within the range shown.
33. With the rack in the straight ahead driving position, cut the wire (D) and slip the lower end of the steering joint on to pinion shaft (E).





34. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Make sure the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure the steering joint is fully seated.
35. Tighten the steering joint bolt to the specified torque.





36. Install the steering joint cover A.
37. Install the front wheel, then set the wheels in the straight ahead position.
38. Install the steering wheel.





39. Holding the tires raised off the ground (lifted up), check for the following symptoms by turning the steering wheel fully to the right and left several times.
40. Reconnect the negative cable to the battery and do the following items:

NOTE: If the IMA battery level gauge (BAT) displays no segments, start the engine, and hold it between 3,500 rpm and 4,000 rpm without load (in Park or neutral) until the BAT displays at least three segments.

^ Power window control unit reset procedure.
^ Enter the anti-shaft codes for the radio and the navigation system, then enter the customer's XM radio channel presets.
^ Set the clock.
^ Verify cruise control, auto remote, navigation voice control, and turn signal switch operation.
^ Make sure the steering wheel is centered.
^ Do the memorizing the torque sensor neutral position.
41. After installation, perform the following checks:
^ Start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on.
^ Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary.
^ Check the front toe inspection.