Steering: Removal & Installation — Honda Fit I (2004-2009)

Removal

Note. Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

Scheme 77

Scheme 77: Removal

Remove the steering gearbox (see «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-291392-S34467870742008072800000) ).
Remove the connector bracket (A).
Remove the EPS motor angle sensor 6P connector (B), the EPS motor 1P connector (C), the EPS motor 2P connector (D), and the clip (E) from the connector bracket.
Remove the heat shield (A) and the EPS motor (B) from the steering gearbox, then remove the O-ring (C) and discard it.

Scheme 78

Scheme 78: Installation

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Clean the mating surface of the EPS motor (A) and the steering gearbox.
Apply a thin coat of silicone grease to the new O-ring (B), and carefully fit it on the EPS motor.
Apply grease (Shell steering gear grease or Honda's equivalent steering gear grease) into the EPS motor shaft (C).
Install the EPS motor on the steering gearbox by engaging the EPS motor shaft and the worm shaft (D).
Before tightening the bolts, turn the EPS motor two or three times to the right and left about 45 degrees. Make sure the EPS motor is evenly seated on the steering gearbox, and that the O-ring is not pinched between the mating surfaces.
Install the heat shield, and in two or more steps, alternately tighten the three bolts on the steering gearbox to the specified torque.
Install the EPS motor angle sensor 6P connector (A), the EPS motor 1P connector (B), the EPS motor 2P connector (C), and the clip (D) to the connector bracket (E).
Install the connector bracket.
Finish the installation, make sure the EPS motor and the EPS wires are not caught or pinched by any parts.
Install the steering gearbox (see «INSTALLATION»(ref-291392-S17877914932008072800000) ).

Special Tools Required

Ball joint thread protector, 12 mm 07AAF-SDAA100
Universal eyelet 07AAK-SNAA120
Ball joint remover, 28 mm 07MAC-SL0A202
Fit Engine hanger adapter VSB02C000026 *
Engine support hanger, A and Reds AAR-T-12566 *

* : These special tools are available through the Honda Tool and Equipment program, 888-424-6857

Note these items during removal

Using solvent and a brush, wash any oil and dirt off the end of the steering gearbox. Avoid any electrical parts. Blow dry with compressed air.
Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.

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Make sure you have the anti-theft code for the audio system.
Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-291386-S27342084212008072800000) ).
Remove the front wheels.
Remove the steering wheel (see «STEERING WHEEL REMOVAL»(ref-291392-S33915606772008072800000) ).
Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-291426-S33073643082008072800000) ).
Remove the steering joint cover (A).
Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column.
Remove the center guide (A) (if equipped), and discard it. The center guide is for factory assembly only.
Remove the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-291400-S28864655392008072800000) ).
Install the universal eyelet (A) to the air cleaner housing bracket (B).
Install the engine support hanger adapter (A) to the engine support hanger (B).
Install the front leg assembly (C), hook (D), and wing nut (E) onto the engine support hanger.
Raise the vehicle on the hoist to full height.
Remove the cotter pin (A) from the 10 mm nut (B), and loosen the nut.
Separate the tie-rod ball joint and the knuckle using the ball joint remover (see «BALL JOINT REMOVAL»(ref-291393-S36855774982008072800000) ).
Remove the clip (A) from the 12 mm castle nut (B), and remove the nut.
Separate the lower arm ball joint and the knuckle using the ball joint remover and the ball joint thread protector (see «BALL JOINT REMOVAL»(ref-291393-S36855774982008072800000) ).
Remove the stabilizer link from the stabilizer bar (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-291419-S23348219732008072800000) ).
Disconnect the torque sensor 4P connector (A), EPS motor angle sensor 6P connector (B), EPS motor 1P connector (C), and EPS motor 2P connector (D) from the driver's side of the steering gearbox. Wrap the connectors with vinyl tape to avoid the contamination from grease or water.
Remove the front splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-291441-S16409066212008072800000) ).
A/T model: Loosen the mounting bolts (A) of the transmission rear mount bracket (B) on the front subframe.
Remove the mounting bolt (C) of the transmission rear mount bracket on the front subframe, and discard it. NOTE: The illustration shows an A/T model.
Attach a wood block (A) to the lower center of the front subframe (B). Attach a jack to the center of the wood block and support the front subframe securely by raising the jack.
Remove the front subframe mounting bolts (C), and discard them.
Lower the front subframe and steering gearbox as an assembly by lowering the jack slowly.
Remove the 10 mm flange bolts, then remove the stiffener plates (A), the gearbox mounting bracket (B) and the mounting cushion (C).
Remove the steering gearbox (D) from the front subframe.
Remove the pinion shaft grommet (A) from the top of the torque sensor.

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Scheme 91: Installation

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Install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the torque sensor. The grommet must not have a gap at the mating surface of the grommet and the torque sensor.
Place the steering gearbox on the front subframe.
Loosely install the stiffener plates (A), and the gearbox mounting bolts on the driver's side of the steering gearbox. NOTE: Use the new mounting bolt (B) and new bolt (C).
Position the cutout (D) on the mounting cushion (E) as shown, and securely install it on the gearbox. NOTE: Make sure to align the tab (F) on the mounting cushion with the paint mark (G) on the steering gearbox.
Install the gearbox mounting bracket (H) over the mounting cushion, and loosely install the 10 mm bolts.
In two or more steps, alternately tighten the 10 mm bolts on both sides of the steering gearbox to the specified torque.
Turn out the lip (I) of the pinion shaft grommet to ease installation.
Set the front subframe (A) mounting with the. steering gearbox on the transmission jack and support it.
Carefully raise the front subframe with the jack, and pass the pinion shaft into the cabin. Return the lip (B) of the pinion shaft grommet. NOTE: Be sure that the pinion shaft grommet is securely in place. Check whether the pinion shaft grommet is not turning up. Incorrect installation can cause leakage of water, mud, or noise. Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
Install the front subframe with new 14 mm flange bolts and tighten to the specified torque.
Install the new mounting bolt (A) on the transmission rear mount bracket (B), and tighten to the specified torque. NOTE: The illustration shows an A/T model.
A/T model: Tighten the mounting bolt (C) on the transmission rear mount bracket to the specified torque.
Install the front splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-291441-S16409066212008072800000) ).
Remove the vinyl tape, then connect the torque sensor 4P connector (A), steering angle sensor 6P connector (B), EPS motor 1P connector (C), and EPS motor 2P connector (D) to the steering gearbox (you will hear a click when the connectors are securely connected).
Connect the stabilizer links to the stabilizer bar (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-291419-S23348219732008072800000) ).
Wipe off any grease contamination from the tapered section and threads of the lower arm ball joint. Then reconnect the lower arm (A) to the knuckle. Install the new 12 mm castle nut (B) and tighten it. NOTE: Be careful not to damage the lower ball joint boot (C). Check the ball joint boot for deformation before connecting the knuckle. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the joint pin clip hole. Do not align the castle nut by loosening it.
Install the new clip (D). NOTE: Insert the clip from the inside to the outside of the vehicle.
Wipe off any grease contamination from the tapered section and the threads of the ball joint. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 10 mm nut (B), and tighten it.
Install the new cotter pin (C), and bend it as shown.
Remove the engine support hanger and the universal eyelet.
Install the air cleaner (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-291400-S28864655392008072800000) ).
Center the steering rack within its stroke.
Adjust the steering column to the full tilt up position.
Insert the upper end of the steering joint onto the steering shaft (A) (line up the bolt hole (B) with the flat portion (C) on the shaft), and loosely install the upper joint bolt.
Slip the lower end of the steering joint onto the pinion shaft taking care to align the gap (D) within the angle shown.
Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower joint bolt (C).
Pull on the steering joint to make sure that the steering joint is fully seated, then tighten the lower joint bolt to the specified torque.
Tighten the upper joint bolt (D) to the specified torque.
Install the steering joint cover (A).
Install the driver's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-291426-S33073643082008072800000) ).
Install the front wheels, then set the wheels in the straight ahead position.
Install the steering wheel (see «STEERING WHEEL INSTALLATION»(ref-291392-S26264866552008072800000) ).
With the tires raised off the ground, check for the following symptoms by turning the steering wheel fully to the right and left several times. SYMPTOM REFERENCE Symptom Probable cause Rubbing sound coming from the lower steering column area. Steering column joint is contacting the cover. Grating sound from the lower steering column area, or a rough feeling during steering. Poor engagement of the pinion shaft serrations. Noise from around the steering wheel during steering. Poor engagement of the SRS cable reel with the steering wheel, or a damaged cable reel.
Reconnect the negative cable to the battery, and do these items: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Enter the anti-theft code for the audio system. Set the clock. Verify cruise control and turn signal switch operation.
After installation, do these checks: 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. Set the steering column to the center tilt position, then do the front toe inspection (see «WHEEL ALIGNMENT»(ref-291393-S40587600142008072800000) ). Make sure the steering wheel is centered. Do the memorizing of the torque sensor neutral position procedure (see «MEMORIZING THE TORQUE SENSOR NEUTRAL POSITION»(ref-291392-S26516219592008072800000) ). Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on.

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Scheme 101: Exploded view

Note. Do not allow dust, dirt, or other foreign materials to enter the gearbox.

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Scheme 102: Removal

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Remove the boot bands (A) and discard them. Remove the tie-rod clips (B), and pull the boots away from the ends of the gearbox.
Unbend the lock washer (A).
Unscrew both rack ends (A) with a wrench. Be careful not to damage the rack shaft surface with the wrench. Remove the rack end, lock washer (B) and rubber stop (C) and discard them.

Note. Hold the flat surfaces of the rack shaft on the pinion shaft side with another wrench.

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Scheme 105: Installation

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Install the new rubber stop (A) and lock washer (B) on the rack shaft. Align the lock washer tabs (C) with the slots (D) in the rack shaft. Install the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack shaft.
Tighten both rack ends. Be careful not to damage the rack shaft surface with the wrench.
Bend the lock washer (A) back against the flat spots (B) on the rack end ball joint housing.
Apply multipurpose grease to the circumference of the rack end joint housing (A) and lock washer.
Apply a light coat of silicone grease (P/N 08798-9013) to the boot fitting grooves (B) on the rack ends.
Center the steering rack within its stroke.
Clean off any grease or contamination from the boot installation grooves (A) around the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.
After installing the boots, wipe the grease off the threaded section (D) of the rack end.
Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
Close the ear portion (A) of the band (B) with commercially available pincers, Oetiker 1098 or equivalent (C).
Slide the rack shaft right and left to be certain that the boots are not deformed or twisted.

Rack Guide Removal/Installation

Note. During removal/installation, do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

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Scheme 111: Rack Guide Removal/Installation

Remove the steering gearbox (see «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-291392-S34467870742008072800000) ).
Loosen the locknut (A), then remove the rack guide screw (B), the spring (C), the disc washer (D), and the rack guide (E).
Replace the O-ring (F) from the rack guide. Wipe the grease off the sliding surface of the rack guide.
Apply multipurpose grease to the new O-ring, then install it to the rack guide.
Apply multipurpose grease to the sliding surface and the circumference of the rack guide, and install it onto the gearbox housing. Wipe the grease off the threaded section of the housing.
Apply multipurpose grease to both ends of the spring, and install it onto the gearbox housing.
Install the disc washer with its convex side facing the rack guide.
Remove the old sealant from the rack guide screw and apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads. Loosely install the rack guide screw on the steering gearbox.
Loosely install the locknut.
Adjust the rack guide screw (see «RACK GUIDE ADJUSTMENT»(ref-291392-S09520010952008072800000) ). After adjusting, check that the rack moves smoothly by sliding the rack right and left.

Scheme 112

Scheme 112: EPS Control Unit Removal/Installation

Make sure you have the anti-theft code for the audio system.
Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION»(ref-291426-S33073643082008072800000) ).
Remove the under-dash fuse/relay box (see step 4 on «DASHBOARD/ STEERING HANGER BEAM REMOVAL/INSTALLATION»(ref-291426-S12330899782008072800000) ).
Disconnect EPS control unit connector A (2P), connector B (2P), connector C (2P), and connector D (28P).
Remove the nuts (E) from the EPS control unit (F).
Remove the EPS control unit.
Install the EPS control unit in the reverse order of removal. NOTE: The EPS control unit has three 2P connectors; make sure they are correctly reconnected. The locations of the three 2P connectors are the top: connector C (RED, WHT/ RED wires), the middle: connector B (GRN wire), the lower: connector A (BLK, WHT/BLU wires).
Reconnect the negative cable to the battery, and do the following items: Enter the anti-theft code for the audio system. Set the clock. If the EPS control unit is replaced, the EPS control unit must memorize the torque sensor neutral position (see «MEMORIZING THE TORQUE SENSOR NEUTRAL POSITION»(ref-291392-S26516219592008072800000) ).
After installation, start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on.

Tie-rod Ball Joint Boot Replacement