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Power Steering Gear Box: Reassembly

  1. Apply the specified fluid to the entire surface of the rack oil seal.
    1. Recommended fluid : PSF-3
  2. Install the oil seal to the specified position in the rack housing.
    Fig 1: Installing Oil Seal To The Specified Position In The Rack Housing
    G00965095Courtesy of HYUNDAI MOTOR CO.
  3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
    1. Recommended fluid : PSF-3
  4. Install the oil seal in the rack bushing.
    Fig 2: Installing Oil Seal In The Rack Bushing
    G00965096Courtesy of HYUNDAI MOTOR CO.
  5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
  6. Apply the specified grease to the rack teeth.

    Recommended grease:  Multipurpose grease SAE J310a, NLGI #2 EP

    NOTE: Do not plug the vent hole in the rack with grease.
    Fig 3: Identifying Rack
    G00965097Courtesy of HYUNDAI MOTOR CO.
  7. Insert the rack into the rack housing and push in the rack bushing until it is aligned with the notched hole of the rack housing, then install it.
    Fig 4: Installing Rack & Rack Bushing
    G00965098Courtesy of HYUNDAI MOTOR CO.
  8. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
  9. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly.
    Fig 5: Identifying Pinion Valve
    G00965099Courtesy of HYUNDAI MOTOR CO.
  10. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly and O-ring in the gear box.
    Fig 6: Installing Valve Body & O-Ring In Gear Box
    G00965100Courtesy of HYUNDAI MOTOR CO.
  11. Install the tie rod and punch on a point over the tie rod with a chisel.
    Fig 7: Punching A Point Over The Tie Rod With A Chisel
    G00965101Courtesy of HYUNDAI MOTOR CO.
  12. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.
    Fig 8: Installing Bushing, Rack Support Yoke, Rack Support Spring & Yoke Plug
    G00965102Courtesy of HYUNDAI MOTOR CO.
  13. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 12 Nm (120 kg.cm, 8.9 lb.ft), with a 14mm socket. Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.

    Tightening torque  50-70 Nm (500-700 kg.cm, 37-52 lb.ft)

  14. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
  15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
    1. Recommended grease : Silicone grease
    2. Install the new attaching band to the bellows.
    NOTE: When the bellows are installed, a new band must be used.
  16. Install the bellows in position, taking care not to twist it.
    Fig 9: Installing Bellows In Position
    G00965103Courtesy of HYUNDAI MOTOR CO.
  17. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.

    Recommended grease

    1. A : POLY LUB GLY 801K or equivalent
    2. B : SHOWA SUNLIGHT MB2 or equivalent

    Dust cover inner side and lip : THREE BOND

    Fig 10: Identifying Dust Cover & Grease
    G00965104Courtesy of HYUNDAI MOTOR CO.
  18. Install the tie rod to the tie rod end.
    Fig 11: Installing Tie Rod End
    G00965105Courtesy of HYUNDAI MOTOR CO.
  19. Check for total pinion preload.
Fig 12: Checking Total Pinion Preload
G00965106Courtesy of HYUNDAI MOTOR CO.
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