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Rack End Removal and Installation: Installation

WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
  1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a workbench as shown. Do not clamp the cylinder part of the gearbox housing in the vise.
    Fig 1: Holding Gearbox Housing Using C-clamp And Wooden Blocks
    G06430543Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack shaft.
    Fig 2: Installing Rubber Stop And Lock Washer
    G06430544Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.
  4. Bend the new lock washer (A) back against the flat spots (B) on the rack end joint housing.
    Fig 3: Bending Lock Washer
    G06430545Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Apply multipurpose grease to the circumference of the rack end joint housing (A).
    Fig 4: Applying Multipurpose Grease To Circumference Of Rack End Joint Housing
    G06430546Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Apply a light coat of silicone grease to the boot grooves (B) on the rack end.
    NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
  7. Center the steering rack within its stroke.
  8. Clean off any grease or contamination from the boot installation grooves (A) around on 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.
    Fig 5: Identifying Boots And Tie-Rod Clips
    G06430547Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
  10. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
    Fig 6: Aligning Tabs With Holes
    G06430548Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Close the ear portion (A) of the boot band (B) with commercially available boot band pliers, Oetiker 1098 or equivalent (C).
    Fig 7: Closing Ear Portion Of Boot Band
    G06430549Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Slide the rack shaft right and left to be certain that the boots are not deformed or twisted.
  13. Install the tie-rod end to the rack end.
  14. Install the heat shield (A), then tighten the bolts to the specified torque.
    Fig 8: Heat Shield Bolts With Torque Specifications
    G06430550Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install the steering gearbox (see INSTALLATION  ).
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