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Honda Odyssey 2004. Manual - part 287

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17-36

Power Steering

Steering Gearbox Overhaul (cont’d)

5. Loosen the locknut (A), then remove the rack guide

screw (B).

6. Remove the spring (C) and the rack guide (D) from

the gearbox.

7. Remove the cylinder lines from the gearbox.

8. Drain the fluid from the cylinder fittings by slowly

moving the steering rack back and forth.

9. Remove the end plug (A) from the gearbox housing,

then remove the nut (B) from the pinion shaft end.

10. Remove the two flange bolts, the valve body unit

(C) and gasket (D) from the gearbox. Check that the
valve turns smoothly by turning the pinion shaft. If
any play or roughness is felt, replace the valve
body unit with a new part if necessary. Do not try to
disassemble the valve body unit.

11. Slide the steering rack all the way to the left.

12. Turn the rack stop (A) counterclockwise until the

end of the circlip (B) sticks out from the hole (C) in
the rack stop. Then turn it clockwise to remove the
circlip (D).

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−

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−

17-37

6 mm

(0.20

0.24 in.)

13. Remove the rack stop (A), rack bushing (B) and

steering rack (C) from the steering gearbox.

14. Remove the O-ring (A) and cylinder end seal (B)

from the rack bushing (C).

15. Carefully pry the piston seal ring (A) and O-ring (B)

off the rack piston. Be careful not to damage the
inside of seal ring groove and piston edges when
removing the seal ring.

16. 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.

17. 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).

18. Install a commercially available bearing separator

(D) on the gearbox housing. Set the steering
gearbox in a press so the gearbox housing points
upward, then push out the cylinder end seal (E)
5

6 mm (0.20

0.24 in.) by pressing on the 24’’

long 3/8’’ drive extension end.

19. Remove the steering gearbox from the press, and

remove the washer from the gearbox.

(cont’d)

03/07/29 09:49:36 61S0X050_170_0037

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Reassembly

17-38

Power Steering

Steering Gearbox Overhaul (cont’d)

07TAF-SZ50100

07LAG-SM4010A or
07LAG-SM40100

20. 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.

21. 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 of 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.

22. Coat the special tool with power steering fluid, then

slide it onto the rack, big end first.

23. 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 sizing tool.

• Replace the piston’s O-ring and seal ring as a set.

24. 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.

25. 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.

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17-39

Press

26. Move the special tool back and forth several times

to make sure the piston seal ring fits snugly in the
piston.

27. Wrap vinyl tape 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 that there is no stepped
portion.

28. 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 damage the lip of the seal with the
edges or teeth of the steering rack.

29. Remove the vinyl tape from the steering rack, then

remove any adhesive residue.

30. 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.

31. Insert a deep socket wrench (A) onto the steering

rack as shown.

32. 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.

33. Remove the tool, and center the steering rack.

(cont’d)

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