How to remove and overhaul a Rack and Pinion assembly on a Honda CRX?

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Remove the steering rack splash shield if equipped, then loosen the rack guide adjusting locknut. Tighten the adjusting screw until it compresses the spring and seats against the guide, then loosen it. Torque it to 35 inch lbs., then back it off 20°. Hold it in that position while adjusting the locknut to 18 ft. lbs. (25 Nm). Recheck the play and move the wheels lock-to-lock to ensure the rack moves freely. Disconnect the negative battery cable, raise the vehicle, and support it safely. Remove the cover panel and steering joint cover, unbolt and separate the steering shaft at the coupling. Drain the power steering fluid by disconnecting the return hose at the box and running the engine while turning the steering wheel lock to lock until fluid stops draining. Remove the gearbox shield if equipped and the front wheels. Remove the cotter pins and unscrew the castle nuts on the tie rod ends, then use a ball joint tool to disconnect the tie rod ends and lift them out of the steering knuckles. If equipped with a manual transaxle, disconnect the shift lever torque rod from the clutch housing, slide the pin retainer out of the way, drive out the spring pin, and disconnect the shift rod. For automatic transaxle, remove the shift cable guide from the floor and pull the shift cable down by hand. Remove the two nuts connecting the exhaust header pipe to the exhaust pipe and remove the exhaust header pipe. Disconnect the three hydraulic lines from the control unit. Slide the tie rod ends all the way to the right and remove the steering rack mounting bolts. Drop the gearbox far enough to permit the end of the pinion shaft to come out of the hole in the frame channel, then rotate it forward until the shaft is pointing rearward. Slide the gearbox to the right until the left tie rod clears the beam, then drop it down and out of the vehicle. Installation is the reverse of removal, torquing the mounting bracket bolts to 29 ft. lbs. (40 Nm). If equipped with a manual transaxle, reinstall the pin retainer after driving in the pin and ensure the projection on the pin retainer is in the hole. Reconnect the fluid lines, tightening the line from the pump to 28 ft. lbs. (38 Nm), the line to the reservoir to 9 ft. lbs. (13 Nm), and the line to the oil cooler to 20 ft. lbs. (29 Nm). Fill the system with fluid and bleed the air from the system. For overhaul, remove the steering rack assembly from the vehicle and support it in a bench vise. Remove the valve body assembly from the gearbox housing, ensuring to take out the O-rings and port orifices. Remove the tie rods from the rack by unbending the lock washers and unscrewing the tie rods. Push the right end of the rack into the housing to avoid scratching the sliding surface, loosen the rack screw locknut, and remove the rack guide from the housing. Remove the 28mm snap ring from the bottom of the housing, then tap the pinion lightly with a plastic mallet to remove it. The pinion bearing can be removed if it shows signs of wear using a bearing puller. Remove the four bolts from the end of the rack cylinder housing and slide the cylinder housing off of the rack. Remove the O-ring, back-up ring, steering rack bushing A, and cylinder spring from the cylinder housing, and carefully remove the end seal. Remove the cylinder, cylinder seal retainer, cylinder cap, and steering rack from the housing, along with the retainer washer from the gear housing. Check the upper pinion bearing for free play and replace it if excess free play is evident. Remove the cylinder and seal retainer from the rack, then take out the O-rings and circlip from the seal retainer before removing the cylinder cap. Remove the bushing stopper and cylinder end seal from the seal retainer, and carefully pry the piston seal ring from the rack. Inspect all sliding surfaces for signs of wear, the rack for broken teeth, the pinion assembly for broken teeth, and the main housing, cylinder, and seal retainer for any signs of wear. Replace all O-rings and any damaged snap rings, checking all bearings for excessive free play and replacing any that are damaged. Lubricate all sliding pieces with power steering fluid before assembly unless otherwise noted. Install a new O-ring on the rack with its narrow edge facing out, then install a piston seal guide tool onto the rack big end first. Position the new piston seal ring on the tool and slide it onto the big end of the tool and onto the O-ring on the rack before removing the tool. Coat new O-rings with grease and install them on the cylinder cap, then slide the cylinder cap onto the seal retainer and install the circlip. Grease the sliding surface of the steering rack bushing and install it on the steering rack with the groove facing the steering rack piston. Grease the sliding surface of the cylinder end seal and slide it onto the rack with the grooves facing opposite the seal slider, then attach the seal retainer to the rack. Push the rack bushing to the seal retainer until the cylinder end seal is seated in the retainer, then install the stopper ring in the groove of the seal retainer. Install the retainer washer on the gear housing, place the gear housing on a workbench, and insert the rack and seal retainer assembly into the housing. Coat the inside of the cylinder with power steering fluid and slide it over the rack assembly, pressing it into the housing until it seats. Install the cylinder spring over the rack, then coat the rack bushing with power steering fluid and install it on the spring. Coat the inside surface of the cylinder with power steering fluid and install the cylinder end seal with the groove facing out. Install the O-ring and back-up ring on the gear housing, carefully position the cylinder on the gear housing, and loosely install the four bolts. Install the steering rack into the cylinder housing, being careful not to damage the rack, then tighten the cylinder housing bolts to 16 ft. lbs. (22 Nm). Press the lower bearing onto the pinion with its shielded side facing down, apply a light coating of grease, and install the 28mm snap ring. Grease the pinion seal and install it on the gear housing using a seal driver. Apply grease to the O-ring and install it in the groove in the housing cap, then install the gear housing cap over the pinion and tighten the flange bolts to 8 ft. lbs. (11 Nm). Install the valve body on the assembly, coat the rack guide with grease, and install the rack guide assembly into the housing. Screw in each of the tie rods to the rack while holding the lock washer so that its tabs are aligned with the slots in the rack, then install the stopper washer with the chamfered side facing out. Tighten the tie rod securely, bend the lock washer back onto the flange, install the bellows over the end of the rack housing, and install the retaining clamp. Finally, install the tie rod ends on the tie rods and fill the tie rod boots with grease before installing the rack into the vehicle and connecting the power steering lines, adjusting the rack as needed.

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