Rack End Removal and Installation: Installation

Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in a vise.

Fig 1: Holding Gearbox Housing Using C-Clamp And Wooden Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the damper (A), a new spacer (B), and a new lock washer (C). Align the lock washer tabs (D) with the flat spots (E) on the rack end ball joint housing. Install the rack end (F) while holding the lock washer in place.
NOTE: Make sure that the tapered side (G) of the damper is facing toward the gearbox.

Fig 2: Installing Damper, Spacer And Lock Washer With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Bend the lock washer tabs (A) back against the flat spots (B) on the rack end joint housing.

Fig 3: Bending Lock Washer Tabs
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Stake the lock washer at the stake point (A) on the rack.

Fig 4: Staking Lock Washer On Rack
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply a light coat of multipurpose grease to the boot installation groove (A) on the rack end.

Fig 5: Applying Light Coat Of Multipurpose Grease To Boot Installation Groove On Rack End
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply a light coat of multipurpose grease to the boot installation groove (A) around the gearbox housing. Install the boot (B) on the rack end with the tie-rod clip (C), and fit the boot end in the installation groove in the housing properly.

Fig 6: Applying Light Coat Of Multipurpose Grease To Boot Installation Groove Around Gearbox Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
After installing the boot, wipe the grease off the threaded section (D) of the rack end.

Fig 7: Aligning Tabs With Holes Of Band
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install a new boot band (A) by aligning the tabs (B) with the holes (C) of the band.
Close the ear portion (A) of the boot band with commercially available boot band pliers, Oetiker 1098 or equivalent (B).

Fig 8: Closing Ear Portion Of Boot Band With Commercially Boot Band Pliers
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Slide the rack right and left to be certain that the boots are not deformed or twisted.
Install the heat shield (A).

Fig 9: Heat Shield With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the tie-rod end and the locknut to the rack end.
Install the steering gearbox (see INSTALLATION ).