Power Steering: Removal & Installation — Honda Pilot I (2002-2005)

Fluid Replacement

Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather.

System Capacity: 1.22 l (1.29 US. Qt.)

System Capacity With Accessory Cooler: 1.26 L (1.33 Us. Qt.)

Reservoir Capacity: 0.4 l (0.42 US. Qt)

Scheme 17

Scheme 17: Fluid Replacement

Scheme 18

Remove the power steering reservoir from its holder. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once.
Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container.
Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid.
Reinstall the return hose on the reservoir.
Fill the reservoir to the upper level line (C).
Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system.
Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line.
If the fluid is contaminated, dark, or discolored, repeat procedure as necessary.

Note these items during installation

Scheme 19

Scheme 19: Power Steering Hose, Line & Pressure Switch Replacement

Scheme 20

Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown.
Check all clamps for deterioration or deformation; replace the clamps with new ones if necessary.
Add the recommended power steering fluid to the specified level on the reservoir and check for leaks.

Scheme 21

Scheme 21: Pump Replacement

Scheme 22

Place a suitable container under the vehicle.
Drain the power steering fluid from the reservoir.
Cover the crankshaft pulley with several shop towels to protect if from spilled power steering fluid. Disconnect the pump inlet hose (A) and pump outlet hose (B) from the pump (C), and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once.
Remove the belt (D) by loosening the pump adjusting nut (E), then remove pump mounting bolt (F), nut (G) and pump. Do not turn the steering wheel with pump removed.
Connect the pump outlet hose and inlet hose to the pump. Tighten the pump fittings securely.
Loosely install the pump in the pump bracket with the mounting bolt and nut.
Install the pump belt (A) on the pulley (B). Note these items during belt installation: Make sure that the power steering belt is properly positioned on the pulleys. Do not get the power steering fluid or grease on the belt or pulley faces. Clean off any fluid or grease before installation.
Adjust the pump belt adjustment (see «PUMP BELT INSPECTION & ADJUSTMENT»(ref-174024-S14356978832005041500000) ).
Fill the reservoir to the upper level line (see «FLUID REPLACEMENT»(ref-174024-S30595022252005041500000) ).

Steering Wheel Removal

SRS components are located in this area. Review the SRS components locations, precautions and procedures in AIR BAG RESTRAINT SYSTEMS before performing repairs or service.

Scheme 23

Scheme 23: Steering Wheel Removal

Scheme 24

Scheme 25

Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel. For 2004 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-170415) . For 2003 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-160405) . ).
Disconnect the horn switch connector (A), radio remote switch connector (B) and cruise control switch connector (C).
Remove the steering wheel nut or bolt. Install a steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column by turning the pressure bolt (C) of the puller. Note these items when removing the steering wheel: Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt.
Remove the steering wheel puller, then remove the steering wheel from the steering column.

Scheme 26

Scheme 26: Steering Wheel Disassembly/Reassembly

Scheme 27

Scheme 27: Steering Wheel Installation

Scheme 28

Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about two and a half turns. The arrow mark (B) on the cable reel label point should point straight up.
Install the steering wheel onto the steering column shaft, making sure the steering wheel hub (A) engages the pins (B) of the cable reel and tabs (C) of the canceling sleeve (D). Do not tap on the steering wheel or steering column shaft when installing the steering wheel.
Install the steering wheel nut and tighten it to 49 N.m (5.0 kgf.m, 36 ft. lbs.).
Connect the horn switch connector, the radio remote switch connector, and the cruise control switch connector.
Install the driver's airbag. For 2004 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-170415) . For 2003 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-160405) .
Connect the battery cable. Confirm that the SRS system is operating properly. For 2004 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-170415) . For 2003 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-160405) . Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft codes for the radio and the navigation system, then the customer's radio station presets. Check the horn, radio remote switch, cruise control set/resume switch and turn signal canceling for proper operation. Set the clock.

Steering Column Removal & Installation

SRS components are located in this area. Review the SRS components locations, precautions and procedures in before performing repairs or service. For 2004 models, see AIR BAG RESTRAINT SYSTEMS . For 2003 models, see AIR BAG RESTRAINT SYSTEMS .

Scheme 29

Scheme 29: Removal

Scheme 30

Record the radio station presets, and disconnect the battery.
Remove the driver's airbag, steering wheel, and cable reel. For 2004 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-170415) . For 2003 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-160405) .
Set the column shaft (A) in the neutral position by pulling up the steering column to uppermost position, then lower it 8 mm (0.31"). Tighten the tilt lever (B).
Remove the column covers (A).
Move the shift lever (B) to the N position, and remove the shift cable from the column, and set it aside.
Remove the combination switch assembly (C) from the steering column shaft by removing the three mounting screws, and disconnecting the connectors.
Disconnect the ignition switch connectors and disconnect the harness clips.
Disconnect the immobilizer receiver unit, the park pin switch, and the shift lock solenoid.
Remove the steering joint cover (D).
Disconnect the steering joint (E), and remove it from the column shaft.
Remove the steering column (F) by removing the attaching nuts and bolts.

Scheme 31

Scheme 31: Installation

Install the steering column and make sure the wires are not caught or pinched by any parts.
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).
Slip the lower end of the steering joint onto the pinion shaft (D) (line up the bolt hole (E) with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft.
Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten lower joint bolt.
Finish the installation in the reverse order of disassembly, and note these items: Make sure the wire harness is routed and fastened properly. Make sure the connectors are properly connected. Reinstall the steering wheel (see «STEERING WHEEL INSTALLATION»(ref-174024-S41373734402005041500000) ). Reconnect the battery. Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft codes for the radio and the navigation system, then the customer's radio station preset's. Set the clock. Verify cruise control, horn, radio remote, and turn signal switch operation. Make sure the steering wheel is centered.

Scheme 32

Scheme 32: Steering Column/Tilt Lever Inspection/Adjustment

Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly.
Check the retaining collar (C) for damage. If it is damaged, replace the steering column as an assembly.
Check the absorbing plates (D), absorbing plate guides (E) and sliding capsules (F) for distortion or breakage. If there is distortion or breakage, replace the steering column as an assembly. The sliding capsule is attached to the column bracket with the plastic injections (G).

Scheme 33

Move the tilt lever (A) from the loose position to the lock position three to five times. With the tilt lever in the loose position measure the tilt lever in the loose position measure the tilt lever preload 10 mm (0.4") from the end of the tilt lever. Preload: 70-90 N (7-9 kgf, 15-20 lbf)
If the measurement is out of the specification, adjust the preload using the following procedures. Loosen the tilt lever, and set the steering column in the neutral position. Remove the 6 mm lock bolt (B), and remove the stop (C). Adjust the preload by turning the tilt lock bolt (D) left or right. Pull up the tilt lever to the uppermost position, and install the stop. Be careful not to loosen the tilt lever when installing the stop or tightening the 6 mm lock bolt. Check the preload again. If the measurement is still out of specification, repeat the above procedures to adjust.

Scheme 34

Scheme 34: Steering Lock Replacement

Scheme 35

Remove the steering column (see «STEERING COLUMN REMOVAL & INSTALLATION»(ref-174024-S02398063972005041500000) ).
Center punch each of the two shear bolts, and drill their heads off with a 5 mm (0.20") drill bit. Be careful not to damage the switch body when removing the shear bolts.
Remove the shear bolts from the switch body.
Install the switch body without the key inserted.
Loosely tighten the new shear bolts.
Insert the ignition key, and check for proper operation of the steering wheel lock. Make sure that the ignition key turns freely.
Tighten the shear bolts (A) until the hex heads (B) twist off.

Steering Gearbox Removal

Special Tools Required

Ball joint remover, 28 mm 07MAC-SL00200

Note these items during removal

Scheme 36

Scheme 36: Steering Gearbox Removal

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air.
Make sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.
Lower the front subframe from the body and remove/install the steering gearbox through the gap produced by lowering the front subframe. Drain the power steering fluid (see step 1 on «FLUID REPLACEMENT»(ref-174024-S30595022252005041500000) ). Record the customer's radio station preset's, then disconnect the battery cable. Remove the driver's airbag assembly. For 2004 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-170415) . For 2003 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-160405) . Remove the steering wheel (see «STEERING WHEEL REMOVAL»(ref-174024-S31522420052005041500000) ). Remove the steering joint cover (A). Remove the steering joint bolts, disconnect the steering joint by moving the steering joint (A) toward the column. Disconnect the pump outlet hose (A) from the power steering pump, and remove the hose clamp (B). Remove the 10 mm flange bolts on the engine side mount bracket (A). Raise the vehicle, and make sure it is securely supported. Remove the front wheels. Remove and discard the cotter pin (A) from the 12 mm nut (B), then loosen the nut. Separate the tie-rod ball joint and knuckle using the special tool (see «BALL JOINT»(ref-166438-S05871034552004092000000) ). Remove the front suspension subframe stiffener. Disconnect the secondary heated oxygen sensor (secondary HO2S) connector (A) from the engine compartment. Remove the three self-locking nuts, and disconnect the three way catalytic converter (TWC) (A) and mufflers (B) (see «EXHAUST PIPE & MUFFLER REPLACEMENT»(ref-173992-S01666815972005041500000) ). Remove the 10 mm flange bolts of the exhaust rubber mount (A). Disconnect the power steering pressure (PSP) switch connector (A). Remove the propeller shaft protector. Remove the splash shield. Place a jack (A) under the front tube of the front suspension subframe (B), and support it by raising the jack. Place a transmission jack (C) under the center of the transfer case (D). Loosen the two 14 mm flange bolts (A) on the front suspension subframe so they are about 30 mm (1 3/16") from the mounting surface. Do not loosen the 14 mm flange bolts more than necessary. Remove the four 12 mm flange bolts from the front suspension subframe front bracket (A). Support the transfer case securely by raising the transmission jack, then remove the two 12 mm flange bolts (A). Remove the two 14 mm special bolts (B) and front suspension subframe rear bracket (C) from the front suspension subframe. Lower the transmission jack slowly until the front suspension subframe has dropped about 50 mm (1 15/16"). Remove the P/S line mounting brackets (A) from the front suspension subframe and gearbox mounting bracket. Loosen the 14 mm flare nut (A), and disconnect the feed line (B). Loosen the adjustable hose clamp (C) and disconnect the return hose (D). Remove the two 10 mm flange bolts from the right side of the gearbox, then remove the mounting bracket (A) and cushion (B). Remove the two 10 mm flange bolts from the left side of the gearbox. Lower the transmission jack slowly until the front suspension subframe has dropped 100 mm (3 15/1") total. Remove the gearbox stiffener bracket (A) from the left side of the front suspension subframe. Slide the steering gearbox (A) between the body and front suspension subframe toward the left, and remove the steering gearbox.

Scheme 60

Scheme 60: Exploded View

Special Tools Required

Cylinder End Seal Remover Attachment 07TAF-SZ50100
Pilot Collar 07GAF-PH70100
Valve Seal Ring Sizing Tool 07NAG-SR3090A
Ball Joint Boot Clip Guide 07974-SA50800
Sleeve Seal Ring Sizing TOOL 07974-SA5020A Or 07974-SA50200
Attachment, 32 X 35 Mm 07746-0010100
Driver 07749-0010000
Piston Seal Ring Guide 07ZAG-S3VA100
Piston Seal Ring Sizing Tool 07ZAG-S3VA200
Pincers, Oetiker 1098 Or Equivalent, Commercially-Available.

Note. Refer to the Exploded View as needed during this procedure.

Removal

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Remove the steering gearbox (see «STEERING GEARBOX REMOVAL»(ref-174024-S37992189982005041500000) ). Disassembly
Remove the boot bands (A) and tie-rod clips (B). Pull the boots away from the ends of the steering gearbox.
Unbend the lock washer.
Hold the flat surface sections (A) of the steering rack (B) with a wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench. Remove the lock washer (D) and stop washer (E).
Loosen the locknut (A), then remove the rack guide screw (B).
Remove the spring (C) and the rack guide (D) from the gearbox.
Remove the cylinder lines from the gearbox.
Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
Loosen the 16 mm flare nut (A), and remove the return line joint (B).
Remove the two flange bolts, then remove the valve body unit (C) from the gearbox (D). Remove the O-ring (E), and discard it.
Drill a 3 mm (0.12") diameter hole about 2.5-3.0 mm (0.10-0.12") in depth in the staked point (A) on the cylinder. Do not allow metal shavings to enter the cylinder housing. After removing the cylinder end (B), remove any burrs at the staked point.
Attach the yoke of a universal puller (A) to the steering gearbox mounts with bolts. Clamp the yoke in a vise with soft jaws as shown, then loosen and remove the cylinder end (B). Do not clamp the cylinder housing or gearbox housing in the vise.
Install a commercially available bearing separator (A) on the gearbox housing as shown.
Place an appropriately sized deep socket wrench (B) on the steering rack (C).
Set the steering gearbox in a press so the gearbox housing points upward, then press the cylinder end seal (D) and steering rack out of the gearbox. Hold the steering rack to keep it from falling when pressed clear. Be careful not to damage the inner surface of the cylinder housing with the tool.
Remove the cylinder end seal from the steering rack.
Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.
Install a washer (O. D. 27.5 mm, P/N 94103-10400) (A) so it will fit through the rack guide hole of the gearbox housing, then position the washer on the cylinder end seal (B). Make sure that the washer is securely positioned on the cylinder end seal edges.
Install the socket wrench with a 27.5 mm O.D. (A) onto the 24" long 3/8" drive extension (B), and carefully place it on the washer (C).
Set the steering gearbox in a press so the gearbox housing points upward, then push out the cylinder end seal (D) 5-6 mm (0.20-0.24") by pressing on the 24" long 3/8" drive extension end.
Remove the steering gearbox from the press, and remove the washer from the gearbox inside.
Turn the special tool so it will fit through the rack guide hole of the steering gearbox, then position the special tool on the cylinder end seal (A). Make sure that the special tool is securely positioned on the seal edges.
Insert a 24" long 3/8" drive extension (A), on the special tool. Place the steering gearbox in a press, then remove the cylinder end seal (B) from the gearbox by pressing on the 24" long 3/8" drive extension. Note these items when pressing the cylinder end seal: Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal. Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the gearbox.
Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft (C).
Separate the valve housing from the pinion shaft/valve using a press.
With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it.
Check for wear, burrs, and other damage to the edges of the grooves in the sleeve.
Remove the snap ring (A) and sleeve (B) from the pinion shaft.
Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.
Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the cutting groove position (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring.
Remove the valve oil seal (A) and wave washer (B) from the pinion shaft. Note these items during disassembly: Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play or wear, replace the pinion shaft and sleeve as an assembly. The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.
Press the valve oil seal (A) and bushing (B) out of the valve housing using a hydraulic press and special tool.
Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in the solvent. Reassembly
Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with power steering fluid.
Install the wave washer (B).
Coat the inside surface of the new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D).
Apply vinyl tape (A) to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with power steering fluid.
Fit the new O-ring (B) in the groove of the pinion shaft. Then slide the new valve seal ring (C) over the shaft and in the groove on the pinion shaft.
Remove the tape, and apply power steering fluid to the surface of the valve seal ring (A).
Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring, and move the special tool up and down several times to make the valve seal ring fit in the pinion shaft groove.
Remove the special tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fits snugly in the pinion shaft groove.
Apply power steering fluid to the surface of the special tool. Slip two new seal rings (A) over the special tool from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B). Note these items when installing the seal ring: Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal rings using the special tool (sizing tool). There are two types of sleeve seal rings: Black and Brown. Do not mix the different types of rings as they are not compatible.
Align the special tool with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.
Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool.
Move the sleeve back and forth several times to make the seal rings snugly fit in the sleeve. Make sure the seal rings are not twisted.
Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve.
Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and special tools. Install the seal with its grooved side facing the tool.
Press the bushing (C) into the valve housing with a hydraulic press and special tool.
Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid.
Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C).
Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.
Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it.
Coat the special tool with power steering fluid, then slide it onto the rack, big end first.
Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly: Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the special tool (sizing tool). Replace piston's O-ring and seal ring as a set.
Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.
Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
Move the special tool back and forth several times to make the piston seal ring fits snugly in the piston.
Wrap vinyl tape (A) around the rack teeth and rack end edges, then coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no steeped portion.
Coat the inside surface of the new cylinder end seal (A) with power steering fluid, then install it onto the steering rack with its grooved side toward the piston. When installing the cylinder end seal, be careful not to damage the lip of the seal with the edges or teeth of the steering rack.
Remove the vinyl tape from the steering rack, then remove any adhesive residue.
Install the new backup ring (A) on the steering rack, then place the cylinder end seal (B) against the piston.
Grease the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage the inner surface of the cylinder wall with the rack edges.
Insert an appropriate size deep socket wrench (A) onto the steering rack as shown.
Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal.
Remove the tool, and center the steering rack.
Wrap vinyl tape around the rack end edges, and coat the surface of the tape with the power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.
Coat the inside surface of the new cylinder end seal with power steering fluid, then install the seal onto the steering rack with its grooved side toward the piston.
Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.
Remove the vinyl tape from the steering rack, then remove any adhesive residue.
Attach the yoke of a universal puller (A) to the steering gearbox mounts with bolts, then clamp the yoke in a vise with soft jaws. Do not clamp the cylinder part of the housing or gearbox housing in the vise.
Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B).
Remove the yoke from the gearbox, then, after tightening the cylinder end (C), stake the point of the cylinder shown (opposite from where the stake was removed during disassembly).
Coat the new O-ring (A) with steering grease (08C35-B0534L), and carefully fit it on the valve housing.
Apply multipurpose grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections).
Tighten the flange bolts (D) to the specified torque.
Install the return line joint (E), and tighten the 16 mm flare nut (F).
Install the cylinder lines. Note these items during reassembly: Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material. Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.
Apply steering grease (08C35-B0534L) the sliding surface of the rack guide (A), and install it onto the gearbox housing.
Remove the old sealant from the rack guide screw (B), then apply new sealant (threebond 1215 or loctite 5699) all around the threads. Install the spring (C), rack guide screw and locknut (D).
Adjust the rack guide screw (see «RACK GUIDE ADJUSTMENT»(ref-174024-S00650661482005041500000) ). After adjusting, check that the rack moves smoothly by sliding it right and left.
Install the new stop washer (A) and lock washer (B) on the rack end (C) in the rack. Align the lock washer tabs (D) with the slots (E). Install the rack end (F) while holding the lock washer in place. Repeat this step for the other side of the rack.
Hold the flat surface sections (G) of the steering rack with a wrench, and tighten both rack ends. Be careful not to damage the rack surface with the wrench.
Bend the lock washer (A) back against the flat spots on the rack end joint housing.
Apply multipurpose grease to the circumference of the rack end joint housing (A).
Apply a light coat of silicone grease to the boot grooves (B) on the rack end.
Center the steering rack within its stroke. Install the boots on the rack ends with the tie-rod clips. After installing the boots, wipe the grease off the threaded section (A) of the rack end.
Install the new boot bands by aligning the tabs (A) with the holes (B) on the band.
Close the ear portion (A) of the band with commercially available pincers Oetiker 1098 or equivalent (B).
Slide the rack right and left to be certain that the boots are not deformed or twisted.

Steering Gearbox Installation

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

Scheme 110

Scheme 110: Steering Gearbox Installation

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Install the pinion shaft grommet (A) on the valve housing.
Slide the steering gearbox (B) between the front suspension subframe and body from the driver's side. Place the gearbox in position on the front suspension subframe.
Install the gearbox stiffener bracket (A) on the front suspension subframe, and tighten the bolt and nut to the specified torque.
Loosely install the two 10 mm flange bolts on the left side of the gearbox.
Install the mounting cushion (A) on the right side of the gearbox.
Install the mounting bracket (B) over the mounting cushion, then install the two 10 mm flange bolts (C). Tighten the four 10 mm flange bolts for the gearbox to the specified torque.
Connect the return hose (A) securely, and tighten the adjustable hose clamp (B) (see «POWER STEERING HOSE, LINE & PRESSURE SWITCH REPLACEMENT»(ref-174024-S35193250982005041500000) ).
Connect the feed line (C), and tighten the 14 mm flare nut (D) to the specified torque.
Install the P/S line mounting brackets (A) on the front suspension subframe and gearbox mounting bracket.
Carefully raise the front suspension subframe with the transmission jack (transfer case supporting jack).
Install the front suspension subframe rear bracket (A). Tighten the 12 mm flange bolts (B) and 14 mm special bolts (C) to specified torque.
Install the front suspension subframe front bracket (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque.
Lower the front subframe supporting jack and the transmission jack.
Install the splash shield (A).
Install the propeller shaft protector.
Connect the power steering pressure (PSP) switch connector (A).
Connect the three way catalytic converter (TWC) (A) and mufflers (B). Install the new 10 mm self-locking nuts and tighten them to specified torque.
Install the exhaust rubber mount on the frame.
Connect the secondary heated oxygen sensor (secondary HO2S) connector (A), and install the wire harness on the clamp and clip. Make sure the wire harness is routed and fastened properly.
Install the front suspension subframe stiffener.
Install the 10 mm flange bolts on the engine side mount bracket (A).
Connect the pump outlet hose (A) from the power steering pump, and install the hose clamp (B).
Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.
Install the new cotter pin (C) and bend it as shown.
Center the steering rack within its stroke, then install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows: Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shaft). Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole (F) with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten lower joint bolt.
Center the cable reel first by rotating it clockwise until it stops. Then rotate it counterclockwise (about two and one-half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel (see «STEERING WHEEL INSTALLATION»(ref-174024-S41373734402005041500000) ).
Install the steering joint cover (A) with the clamps (B) and clips (C).
Install the front wheels.
Connect the battery cable. Do the PCM idle learn procedure (see «PCM IDLE LEARN PROCEDURE»(ref-173998-S03649363492005041500000) ). Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-174055-S11132043692005042800000) ). Enter the anti-theft codes for the radio and the navigation system, then the customer's radio station preset's. Set the clock.
Fill the system with power steering fluid, and bleed air from the system (see «FLUID REPLACEMENT»(ref-174024-S30595022252005041500000) ).
After installation, perform the following: Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks (see «FLUID LEAKAGE INSPECTION»(ref-174024-S35299067842005041500000) ). Adjust the front toe (see «TOE-IN ADJUSTMENT»(ref-161551-S14613684932004041400000) ). Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally, if necessary.

Power Steering: Removal & Installation Honda Pilot I