How to replace rack and pinion on 2001 Honda odyssey?

Removal & Installation

2001-04 Models

WARNING

Do not permit the steering wheel to turn whenever the steering gear is disconnected from the steering column. Damage to the air bag wiring can result.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Center the steering wheel and lock it in position.
3. Attach a support fixture to the engine lifting eyes.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Drivers side air bag assembly, if equipped

   Steering joint cover

   Steering flexible joint

   Front wheels

   Outer tie rod ends

   Splash shield

   Heated Oxygen Sensor (HO ₂ S) connectors

   Exhaust front pipe

   Fuel feed line

   Power steering fluid lines

   Rear engine mount
   
   
5. Support the front subframe with a jack.
6. Loosen the 14mm subframe bolts and remove the 12mm stiffener plate bolts.
7. Lower the subframe about 1 ³ / ₁₆ inches (30mm).
8. Remove or disconnect the following:
   
   
   Right steering gear mounting bracket

   Left steering gear mounting bolts

   Steering gear
   
   

To install:

Fig. Make sure the right steering gear mounting bracket is oriented properly-2001-04 models

1. Position the steering gear in the vehicle.
2. Install or connect the following:
   
   
   Left steering gear mounting bolts. Tighten the bolts to 43 ft. lbs. (58 Nm).

   Right steering gear mounting bracket. Tighten the bolts to 29 ft. lbs. (39 Nm).
   
   
3. Raise the subframe into position. Tighten the 14mm bolts to 76 ft. lbs. (103 Nm) and the 12mm bolts to 54 ft. lbs. (74 Nm).
4. Install or connect the following:
   
   
   Rear engine mount

   Power steering fluid lines

   Exhaust front pipe

   HO ₂ S connectors

   Splash shield

   Outer tie rod ends

   Front wheels. Position the wheels straight-ahead.

   Steering flexible joint. Tighten the pinch bolts to 16 ft. lbs. (22 Nm).

   Steering joint cover

   Negative battery cable
   
   
5. Fill the power steering system.
6. Check the wheel alignment and adjust as necessary.

2005-06 Models

1. Drain the power steering fluid.
2. Record the radio station preset.
3. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work.
4. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector from the cable reel.
   
   
   

   

   Fig. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector from the cable reel-2005-06 models

5. Using a Torx® T30 bit, remove the two Torx® bolts (A).
   
   
   

   

   Fig. Using a Torx® T30 bit, remove the two Torx® bolts (A) -2005-06 models

6. Disconnect the horn switch connector (1P), then remove the driver's airbag.
7. Align the front wheels straight ahead.
8. Disconnect the cable reel sub-harness connector from the cable reel.
9. Loosen the steering wheel nut three full turns.
   
   
   

   

   Fig. Steering wheel puller

10. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller.
11. Note these items when removing the steering wheel:
    1. Do not tap on the steering wheel or the steering column shaft when removing the steering wheel.
    2. 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.

    
    
12. Remove the steering wheel puller, then remove the steering wheel nut and steering wheel from the steering column.
13. Remove the steering joint cover.
    
    
    

    

    Fig. Remove the steering joint bolts, disconnect the steering joint by moving the steering joint (A) toward the column-2005-06 models

14. Remove the steering joint bolts, disconnect the steering joint by moving the steering joint (A) toward the column.
    
    
    

    

    Fig. Remove the cotter pin (A) from the 12 mm nut (B), and loosen the nut-2005-06 models

15. Remove the cotter pin (A) from the 12 mm nut (B), and loosen the nut.
16. Separate the tie-rod ball joint and knuckle using the special tool.
17. Remove the 10 mm flange bolts of the exhaust rubber mount (A).
    
    
    

    

    Fig. Remove the 10 mm flange bolts of the exhaust rubber mount (A)-2005-06 models

18. Remove the three self-locking nuts, and disconnect the three way catalytic converter (TWC) from the muffler.
19. Remove exhaust pipe A.
20. Disconnect the power steering pressure (PSP) switch connector (A).
21. Remove the front splash shield (A).
22. Attach the special tool to the front subframe (A) by hanging the hook of the special tool over the front of the subframe, then tighten the special tool screw.
    
    
    

    

    Fig. Attach the special tool to the front subframe (A) by hanging the belt (B) of the special tool over the front of the subframe, secure it with the pin (C), then tighten the special tool screw-2005-06 models

23. Raise the jack (B) and line up the slots in the arms with the bolt holes on the corner of the jack base, then attach them with bolts securely.
    
    
    

    

    Fig. Loosen the front subframe front bracket (A) mounting bolts on the right and left of the vehicle so they are about 30 mm (13/16 in.) from the mounting surface-2005-06 models

24. Loosen the front subframe front bracket (A) mounting bolts on the right and left of the vehicle so they are about 30 mm (1 ³ / ₁₆ in.) from the mounting surface.
25. Support the front subframe securely by raising the special tool, then remove the two 12 mm flange bolts (A).
26. Remove the two 14 mm special bolts (B) and front subframe rear brackets (C) from the front subframe.
    
    
    

    

    Fig. Support the front subframe securely by raising the special tool, then remove the two 12 mm flange bolts (A). Remove the two 14 mm special bolts (B) and front subframe rear brackets (C) from the front subframe. Lower the jack supporting the front subframe with the special tool slowly until the front subframe has dropped about 50 mm (115/16 in.)-2005-06 models

27. Lower the jack supporting the front subframe with the special tool slowly until the front subframe has dropped about 50 mm (1 ¹⁵ / ₁₆ in.).
28. Remove the P/S line mounting brackets from the front subframe and gearbox mounting bracket.
29. Loosen the 16 mm flare nut, and disconnect the feed line from the gear box.
30. Loosen the adjustable hose clamp and disconnect the return hose.
31. Remove the P/S heat baffle plate.
32. Remove the two 10 mm flange bolts from the right side of the steering gearbox, then remove the mounting bracket (A) and cushion (B).
    
    
    

    

    Fig. Remove the two 10 mm flange bolts from the right side of the steering gearbox, then remove the mounting bracket (A) and cushion (B)-2005-06 models

33. Remove the two 10 mm flange bolts and nuts from the left side of the gearbox.
    
    
    

    

    Fig. Remove the two 10 mm flange bolts and nuts from the left side of the gearbox-2005-06 models

34. Loosen the steering gearbox bracket mounting bolts (A).
    
    
    

    

    Fig. Loosen the steering gearbox bracket mounting bolts (A)-2005-06 models

35. EX-L, EX-L Touring models:
    1. Remove the rear mount stop (A), then remove the rear mount bolt (B).
       
       
       

       

       Fig. Remove the rear mount stop (A), then remove the rear mount bolt (B)-EX-L, EX-L Touring models-2005-06 models

    2. Remove the rear mount (A) from the base bracket (B), and disconnect the connector (C).
       
       
       

       

       Fig. Remove the rear mount (A) from the base bracket (B), and disconnect the connector (C)-EX-L, EX-L Touring models-2005-06 models

    3. Remove the base bracket from the front subframe.

    
    
36. VAN, LX, EX models
    1. Remove the rear mount bracket bolt (A).
       
       
       

       

       Fig. Remove the rear mount bracket bolt (A)-Van, LX, EX models-2005-06 models

    2. Remove the rear mount bracket from the front subframe.

    
    
37. Disconnect the return hose clip.
38. Move the steering gearbox to the driver's side, and rotate it so the pinion shaft points toward the front of the vehicle.
39. Carefully move the steering gearbox as an assembly toward the left side of the vehicle until the pinion shaft clears the wheel well opening. Be careful not to damage the brake lines with the pinion shaft.
40. Remove the steering gearbox through the wheel well opening on the driver's side.
41. Remove the pinion shaft grommet from the steering joint cover B.
42. After removing the steering gearbox, make sure that no power steering fluid gets on the gearbox mount cushions, gearbox housing, surface of the front subframe and stiffener. Wipe off any spilled fluid at once.

To install:

1. Install the pinion shaft grommet on the valve housing.
2. Slide the steering gearbox between the front subframe and body from the driver's side. Place the gearbox in position on the front suspension subframe.
3. Rotate the steering gearbox so the pinion shaft points upward.
4. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. Make sure the power steering return line and feed line are routed above the gearbox.
5. Connect the return hose clip.
6. EX-L, EX-L Touring models:
   1. Install the base bracket (A) on the front subframe (B).
      
      
      

      

      Fig. Install the base bracket (A) on the front subframe (B)- EX-L, EX-L Touring models-2005-06 models

   2. Install the rear mount (A) on the base bracket (B), and connect the connector (C).
   3. Install the rear mount stop (A), then install the rear mount bolt (B).

   
   
7. Van, LX, EX models:
   1. Install the rear mount bracket (A) on the front subframe (B).
      
      
      

      

      Fig. Install the rear mount bracket (A) on the front subframe (B)- Van, LX, EX models-2005-06 models

   2. Install the rear mount bracket bolt (A).

   
   
8. Install the steering gearbox bracket mounting bolts (A).
9. Install the two 12 mm flange bolts and nuts on the left side of the gearbox.
10. Install the two 10 mm flange bolts on the right side of the steering gearbox, then install the mounting bracket and cushion.
11. Install the P/S heat baffle plate (A).
    
    
    

    

    Fig. Install the P/S heat baffle plate (A)-2005-06 models

12. Tighten the return hose flare nut (A) to the specified torque, and install the adjustable hose clamp (B) and the return hose (C).
    
    
    

    

    Fig. Tighten the return hose flare nut (A) to the specified torque, and install the adjustable hose clamp (B) and the return hose (C)-2005-06 models

13. Tighten the feed line flare nut to 37 Nm (27 ft. lbs.).
14. Install the P/S line mounting brackets on the front subframe and gearbox mounting bracket.
15. Install the front subframe rear bracket (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque.
    
    
    

    

    Fig. Install the front subframe rear bracket (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque-2005-06 models

16. Install the front subframe front bracket (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque.
    
    
    

    

    Fig. Install the front subframe front bracket (A) with 12 mm flange bolts (B) and 14 mm special bolts (C), and tighten to specified torque-2005-06 models

17. Install the front splash shield.
    
    
    

    

    Fig. Front splash shield installation-2005-06 models

18. Connect the power steering pressure (PSP) switch connector.
19. Install exhaust pipe A using new gaskets and new self-locking nuts.
20. Connect the three way catalytic converter (TWC) (A) to the muffler (B).
21. Install the new 10 mm self-locking nuts, and tighten them to 33 Nm (25 ft. lbs.).
22. Install the exhaust rubber mount on the frame. Torque to 22 Nm (16 ft. lbs.).
23. 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.
    
    
    

    

    Fig. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it. Install a new cotter pin (C), and bend it as shown-2005-06 models

24. Install a new cotter pin (C), and bend it as shown.
25. Center the steering rack within its stroke.
26. 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), and loosely install the upper joint bolt.
27. Slip the lower end of the steering joint onto the pinion shaft (D) taking care to align the gap (E) within the angle.
    
    
    

    

    Fig. 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), and loosely install the upper joint bolt. Slip the lower end of the steering joint onto the pinion shaft (D) taking care to align the gap (E) within the angle-2005-06 models

28. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower joint bolt (C).
29. 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.
30. Tighten the upper joint bolt (D) to the specified torque.
    
    
    

    

    Fig. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower joint bolt (C). 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. Tighten the upper joint bolt (D) to the specified torque-2005-06 models

31. Reinstall the steering joint cover.
32. 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 three full turns. The arrow mark (B) on the cable reel label point should point straight up.
    
    
    

    

    Fig. 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 three full turns. The arrow mark (B) on the cable reel label point should point straight up-2005-06 models

33. Install the steering wheel on to the steering column shaft, making sure the steering wheel hub (A) engages the pins (B) of the cable reel and tabs (C) of the turn signal canceling sleeve (D). Do not tap on the steering wheel or steering column shaft when installing the steering wheel.
    
    
    

    

    Fig. Install the steering wheel on to the steering column shaft, making sure the steering wheel hub (A) engages the pins (B) of the cable reel and tabs (C) of the turn signal canceling sleeve (D). Do not tap on the steering wheel or steering column shaft when installing the steering wheel-2005-06 models

34. Install the steering wheel nut and tighten it to 49 Nm (36 ft. lbs.).
35. Connect the cable reel sub-harness connector.
36. Enter the anti-theft codes for the radio and the navigation system, then enter the audio presets.
37. Without navigation: Reset the clock.
38. Check the cruise control, radio remote, navigation system, and turn signal canceling for proper operation
39. Place the new driver's airbag in the steering wheel, and secure it with new Torx® bolts. Tighten to 10 Nm (84 inch lbs.).
40. Connect the cable reel to the driver's airbag 4P connector, then install the access panel on the steering wheel.
41. Connect the battery negative cable.
42. After installing the airbag, confirm proper system operation:
    1. Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
    2. Make sure the horn button works.

    
    
43. Install the front wheel, then set the wheels in the straight ahead position.
44. Fill the system with power steering fluid, and bleed air from the system.
45. After installation, do the following checks.
    1. Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up to the fluid. Check the gearbox for leaks.
    2. Do the front toe inspection.
    3. Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods equally if necessary.