DYI: 8th Gen Civic Steering Rack Passenger Side going over bumps knock fix
 

NOTE: This Guide Applies for all Power Steering Civics. I don't know if this applies for the SI's Electric Power Steering.

DYI SYMPTOMS TO BE FIXED:
This guide aims to fix an annoying knock usually felt when going in rough surfaces in most cases when only the passenger side hits a bump. Roads with rocks will reproduce this noise A LOT.
Before doing this I tried lots of stuff to fix it:
- Retorqued the 6 Steering rack bolts
- Replaced the Passenger side inner tie rod
- Replaced the Passenger side sway bar links
- Tighten the Steering rack guide screw
All of these attempts did not get rid of this annoying noise. So I decided to go further and replace the steering rack End Cylinder.
Please note my civic is a 2006 EX and has only 62k miles.

DIFFICULTY:
Me not being a mechanic at all, just a car fan I would rate it 5 out of 10 in terms of difficulty. Lets be clear if you know how to replace an Inner rod, this is just another walk in the park for you.

PARTS NEEDED:
- 53630-SNA-A01 - End Cylinder (Aprox $22)
- 53449-S84-A01 - Band Bellows (Aprox $5)
- 53536-SDA-A02 - Washer, tie rod lock (Aprox $1)


STEPS:
1- Loosen passenger side wheel nuts and raise vehicle from this side.
2- Place a jack stand for extra safety and remove the passenger side wheel
3- Apply some WD40 in the alignment nut of the inner tie rod and after a couple of minutes loosen the adjusting nut
4- I recommend cleaning and painting the threads here to maintain Alignment.
http://i1240.photobucket.com/albums/...psg6b0k9nd.jpg
5- Start loosening the tierod in a CLOCKWISE orientation COUNTING THE TURNS for extra assurance of maintaining the wheel alignment. Remove boot.
6- Turn your steering wheel all the way to the left. Hit the Tie Rod Locks or try twisting these so you can loosen the rod. I used an adjustable wrench but I know there are special tools for this.
7- Once the Tie rod is out, turn your steering wheel all the way to the right.
8- Locate a pre done hole and drill a 3mm hole on it. You can refer to the step #11 of this guide...
Steering Gearbox Overhaul - Power Steering I think this is needed to just allow metal shaving out while loosening the End Cylinder.
9- Loosen the End Cylinder using a 41mm Socket
10- Clean rack, threads really well. Put the new End Cylinder in and tighten it to 93 N·m (9.5 kgf·m, 69 lbf·ft).
http://i1240.photobucket.com/albums/...pstgcic2ls.jpg
11- Assembly is reverse of removal, Please use NEW tie rod lock washer (53449-S84-A01) and new Boot band (53536-SDA-A02). Tighten inner tie rod to 93 N·m (9.5 kgf·m, 69 lbf·ft)
http://i1240.photobucket.com/albums/...pswyqqjoxw.jpg

Following this steps I was able to remove this annoying noise. I hear no mor knocks on the passenger side wheel now. =)
Hope this guide helps!