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Steering Gearbox 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. Before installing the steering gearbox, make sure that no grease is on the mating surface of the steering gearbox and the front subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove any grease from the bolt holes.
  2. Install the pinion shaft grommet (A). Align the ledge portion (B) in the pinion shaft grommet with the lug portion (C) on the torque sensor 3P connector. The grommet must not have a gap at the mating surface of the grommet and torque sensor.
    Fig 1: Aligning Ledge Portion In Pinion Shaft Grommet
    G06430525Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Place the steering gearbox (A) on the front subframe (B).
    Fig 2: Steering Gearbox With Torque Specifications On Front Subframe
    G06430526Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Loosely install the stiffener plates (C), and new gearbox mounting bolts, then tighten the bolts to the specified torque in the sequence shown.
  5. Turn the lip (D) of the pinion shaft grommet to ease installation.
  6. Set the front subframe (A) with the steering gearbox on the transmission jack, and support it.
    Fig 3: Setting Front Subframe With Steering Gearbox With Torque Specifications On Transmission Jack
    G06430527Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Carefully raise the front subframe with transmission jack, and pass the pinion shaft into the passenger's compartment.
    NOTE:
    • Be sure that the pinion shaft grommet (B) is securely in place. Make sure the lip of the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water or mud, or noise.
    • Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
  8. Loosely install new front subframe mounting bolts, then tighten the bolts to the specified torque in the sequence shown.
  9. Install the torque rod (A).
    NOTE: Be sure to install the torque rod with the "UP" mark facing up.
    Fig 4: Torque Rod And Mounting Bolts With Torque Specifications
    G00500449Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.
  11. Remove the jack (A).
    Fig 5: Removing Jack
    G06430529Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install the secondary HO2S harness bracket (A) on the steering gearbox.
    Fig 6: Secondary HO2S Harness Bracket With Torque Specifications On Steering Gearbox
    G06430530Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Remove the vinyl tape from the connectors.
  14. Connect the EPS motor 2P connector (A) and the torque sensor 4P connector (B) to the torque sensor.
    Fig 7: Identifying EPS Motor 2P Connector And Torque Sensor 4P Connector
    G06430531Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Install the splash shield (see SPLASH SHIELD REPLACEMENT ).
  16. Connect the stabilizer links (see STABILIZER LINK REMOVAL/INSTALLATION ).
  17. Lower the vehicle.
  18. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod end ball joints (A) to the knuckles. Install the nuts (B), and tighten to the specified torque on both sides.
    Fig 8: Tie-Rod End Ball Joints And Nuts With Torque Specifications
    G06430532Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Install the new cotter pin (C), and bend it as shown.
  20. Wipe off any grease contamination from the lower arm ball joint tapered section and threads. Then reconnect the lower arm (A) to the knuckle. Install the new castle nut (B) and tighten it on both sides.
    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.
    Fig 9: Lower Ball Joint Boot With Torque Specifications
    G06430533Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the clip (D).
  22. Install the front wheels, then set the wheels in the straight ahead position.
    NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
  23. Cut the wire (A).
    Fig 10: Identifying Lower End Of Steering Joint
    G06430534Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. Slip the lower end of the steering joint (B) onto the pinion shaft (C) taking care to align the gap (D) within the angle shown.
  25. Remove the steering wheel holder tool.
  26. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower steering joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft.
    Fig 11: Aligning Bolt Hole With Torque Specifications On Steering Joint
    G06430535Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. 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.
  28. Install the steering joint cover (A).
    Fig 12: Identifying Steering Joint Cover
    G06430536Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. 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 CHART

    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.
  30. Do the 12 volt battery terminal reconnection procedure (see 12 VOLT BATTERY TERMINAL DISCONNECTION AND RECONNECTION ), and do these tasks:
    • Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off.
    • Make sure the horn and turn signal switches work properly.
    • Make sure the steering wheel switches work properly.
  31. Do the memorizing of the torque sensor neutral position (see HOW TO RETRIEVE DTCS  ).
  32. After installation, do these checks:
    • Start the engine, allow it to idle, and turn the steering wheel to full left or full right.
    • Check that the EPS indicator does not come on.
    • 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, then adjust the front toe by turning the tie-rod ends, if necessary.
  33. Check the wheel alignment, and adjust it if necessary (see WHEEL ALIGNMENT ).
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