Acura RL (1996-2004 year). Manual — part 487
51. Coat the inside surface of the cylinder end with
power steering fluid, then install the cylinder end by
screwing it into the gearbox housing.
52. Remove the tool from the gearbox housing.
53. After tightening the cylinder end, stake the point of
the cylinder shown below. For '99 - 01 models go to
step 56.
NOTE: Stake the cylinder in the position opposite
from where the stake was removed during disas-
sembly.
54. Select the 44 mm shim(s) ('96 - 98 models only).
NOTE: Only reinstall the original 44 mm shim(s) when
the steering gearbox is reassembled without replacing
the pinion shaft, valve housing, and gearbox housing
with new ones.
If the pinion shaft, valve housing, and gearbox housing
are replaced, select the new shim(s) as follows.
Shim selection:
a. Set the four 44 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 44 mm shims (Thickness: 0.10 mm,
0.15 mm, 0.20 mm, 0.25 mm respectively)
CAUTION: The four 44 mm shims do not have
thickness identification marks. Measure the thick-
ness of each shim using a micrometer, and mark
the shim for identification.
b. Install the valve body unit on the gearbox housing,
and tighten the flange bolts to the specified torque.
c. Measure the clearance between the gearbox housing
and valve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midway
between the two mounting bolts.
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Reassembly (cont'd)
d. Determine the required thickness of the 44 mm
shims by subtracting the clearance obtained in the
step - "C" from the total thickness of the four shims.
(Total thickness of the four shims) - (Clearance) =
Required thickness of the shims
NOTE: 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):
0.07 - 0.28 = 0.42 mm (0.028 - 0.011 = 0.017 in)
The selected shims should be 0.25 mm (0.010 in) and
0.15 mm (0.006 in) in thickness.
If the required shim thickness is 0.10 mm or less, no
shims are necessary.
55. Set the selected 44 mm shims on the bearing surface
of the gearbox housing.
60. Install cylinder lines A and B.
NOTE:
• Clean the joints of cylinder lines A and B
thoroughly. The joints must be free of foreign
material.
• Install cylinder lines A and B by lighting the flare
nuts by hand first, then tighten the flare nuts to
the specified torque.
Power Steering Gearbox
61. Grease the sliding surface of the rack guide, and
install it onto the gearbox housing.
62. For '96 - 98 models: Apply a thin coat of grease to
the new 0-ring, and install it on the rack guide screw.
For '99 - 01 models: Apply sealant to the all around
threads on the rack guide screw.
63. Install the spring, rack guide screw and locknut on
the gearbox housing.
64. Adjust the rack guide screw (see page
).
NOTE: After adjusting, check that the rack moves
smoothly by sliding the rack right and left.
56. Coat the new O-ring with grease, and carefully fit it
on the valve housing.
57. Apply grease to the needle bearing in the gearbox
housing.
58. Install the valve body unit on the gearbox housing
by engaging the gears.
NOTE: Note the valve body unit installation position
(direction of line connection).
59. Tighten the flange bolts to the specified 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.
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75. Slide the rack right and left to be certain that the
boots are not deformed or twisted.
78. Loosely install the tie-rod locknuts and tie-rod ends
on the rack ends.
73. Bend both sets of locking tabs.
74. Lightly tap on the doubled-over portions to reduce
their height.
CAUTION: Stake the band locking tabs firmly.
76. Install the three lines (6 mm return line, 10 mm
return line and sensor inlet line) to the valve body
unit as shown.
77. Install the line mounting cushions by aligning the
marks on the 10 mm return line (large diameter
line).
Reassembly (cont'd)
72. Install the new boot bands on the boots as shown.
Power Steering Gearbox
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