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Steering Gear: Reassembly

  1. Apply Dexron-II ATF to all "O" rings. Use multipurpose grease to lubricate rack teeth, bearings and teeth on pinion valve assembly. Reassemble in reverse order of disassembly.
  2. Using Driver Handle (09555-21000 ) and appropriate gauge, guide and installer, install back-up washer and oil seal in gear housing. See POWER STEERING GEAR ASSEMBLY EQUIPMENT  table. See Fig 1 . Using correct bearing installer, install new bearings (needle, taper or ball) in gear housing.
    Fig 1: Installing Seal To Gear Housing
    G93J00975Courtesy of HYUNDAI MOTOR CO.
  3. Using correct seal installer, install rack bushing seal. Install new "O" ring onto rack bushing. Install lubricated rack into gear housing. DO NOT cover rack vent hole with grease.
  4. Install rack bushing and rack stopper. Push in rack stopper until snap ring groove of rack stopper is aligned with slotted hole in rack housing. Install circlip while turning rack stopper. When installed, end of circlip should not be visible through slotted hole in rack housing. See Fig 2 .
    POWER STEERING GEAR ASSEMBLY EQUIPMENT

    Application Part No.
    Elantra, Excel & Scoupe
    Rack Oil Seal Installer Gauge 09573-21000
    Rack Oil Seal Installer 09573-21100
    Rack Oil Seal Installer Guide 09573-21200
    Gear Housing Tapered Bearing Installer 09432-21600
    Gear Housing Ball Bearing Installer 09222-21100
    Rack Bushing Oil Seal Installer 09434-14200
    Valve Body Oil Seal Installer 09434-14200
    Rack Support Cover Socket 09565-21100
    Sonata (Mando-Type)
    Rack Oil Seal Installer Gauge 09573-21000
    Rack Oil Seal Installer 09573-33000
    Rack Oil Seal Installer Guide 09573-33100
    Gear Housing Needle Bearing Installer 09222-21100
    Gear Housing Seal Installer 09431-11000
    Rack Bushing Oil Seal Installer 09431-11000
    Gear Housing Ball Bearing Installer 09222-21100
    Valve Housing Oil Seal Installer 09432-21601
    Fig 2: Positioning Circlip
    G90I07779Courtesy of HYUNDAI MOTOR CO.
  5. On Elantra, Excel and Scoupe, use Installer (09432-21600 ) to install oil seal and ball bearing into valve body. On Elantra, install sealing rings onto pinion valve assembly. On all models, apply multipurpose grease to pinion valve assembly gears and Dexron-II fluid to valving areas. See Fig 3 . Install pinion valve into gear housing.
    Fig 3: Lubricating Pinion Valve Assembly
    G90I02734Courtesy of HYUNDAI MOTOR CO.
  6. On Elantra, Excel and Scoupe, use Seal Installer (09434-14200 ) to install seal and bearing into valve body housing. On Sonata, use Bearing Installer (09222-21100 ) and Seal Installer (09432-21601 ) to install bearing and seal into valve housing. See Fig 4 -8 . Install snap ring.
  7. On Elantra, Excel and Scoupe, install new gear housing-to-gear box oil seal and install gear box to rack housing. On all models, install the tab washer and then the tie rod. Align the tab washer tabs with grooves in rack. Stake tab washer into place.
  8. With the pinion shaft turned fully clockwise, tighten a new self-locking nut to specification. Tighten end plug to specification. Using a punch, stake the plug in 2 locations on its circumference.
    Fig 4: Exploded View Of Power Steering Gear (Elantra)
    G93A00976Courtesy of HYUNDAI MOTOR CO.
    Fig 5: Exploded View Of Power Steering Gear (Excel & Scoupe With Mando Gear Box)
    G90H00973Courtesy of HYUNDAI MOTOR CO.
    Fig 6: Exploded View Of Power Steering Gear (Sonata 4-Cylinder & V6 With Mando Gear Box)
    G90A02730Courtesy of HYUNDAI MOTOR CO.
    Fig 7: Exploded View Of Power Steering Gear (Sonata V6 & Scoupe W/ TRW Gear Box)
    G91C00044Courtesy of HYUNDAI MOTOR CO.
  9. Install rack support bushing, rack support and rack support spring into rack. Center rack in housing. Install rack support cover. Move rack to center position. Tighten rack support cover to 11 ft. lbs. (15 N.m). for Elantra or 15-18 ft. lbs. (20-25 N.m) for all others.
  10. Loosen cover approximately 30-60 degrees on Sonata or approximately 10 degrees on all others. Install lock nut and tighten to specification. See TORQUE SPECIFICATIONS  table at end of article.
  11. On all models, install hydraulic feed tubes. Lubricate bellows attaching groove in tie rod with multipurpose grease. Slide new rubber bellows boot attaching band onto tie rod.
  12. Carefully install bellows in position. DO NOT twist bellows. Install attaching band onto bellows. Fill tie rod end with multipurpose grease, and install new dust cover with clip ring.
  13. Install tie rod ends. Adjust length of each tie rod. Measure from outer edge of clamped bellows boot to outer edge of tie rod lock nut. See TIE ROD INSTALLED LENGTH  table. Check and adjust pinion preload as necessary. See PINION PRELOAD  under ADJUSTMENTS.
TIE ROD INSTALLED LENGTH

Application In. (mm)
Elantra 7.1 (181)
Excel and Scoupe (Mando-Type) 6.86-6.94 (174.3-176.3)
Scoupe (TRW-Type) 6.93 (176.1)
Sonata 4-Cylinder 7.38 (187.4)
Sonata V6
Mando-Type 7.38 (187.4)
TRW-Type 6.93 (176.1)
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