Power Steering Gear Box: Disassembly

Remove the tie rod end (A) from the tie rod (B).

Fig 1: Removing Tie Rod End From Tie Rod
Courtesy of HYUNDAI MOTOR CO.
After mounting the tie rod end (A) in a vise, remove the dust cover (B) from the ball joint.

Fig 2: Removing Dust Cover From Ball Joint
Courtesy of HYUNDAI MOTOR CO.
Remove the bellows band (A).

Fig 3: Removing Bellows Band
Courtesy of HYUNDAI MOTOR CO.
Remove the bellows clip (A).

Fig 4: Removing Bellows Clip
Courtesy of HYUNDAI MOTOR CO.
Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
Remove the feed tube from the rack housing.
While moving the rack slowly, drain the fluid from the rack housing.
Unstake the tab washer (A) which fixes the tie rod (B) and rack (C) with a chisel.

Fig 5: Unstaking Tab Washer
Courtesy of HYUNDAI MOTOR CO.
Remove the tie rod (A) from the rack (B).
CAUTION: Remove the tie rod (A) from the rack (B), taking care not to twist the rack.

Fig 6: Removing Tie Rod From Rack
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug locking nut (A), and then remove the yoke plug.

Fig 7: Removing Yoke Plug Locking Nut
Courtesy of HYUNDAI MOTOR CO.
Remove the lock nut (A), yoke plug (B), rack support spring (C), rack support yoke (D) and bushing (E) from the gear box.

Fig 8: Identifying Lock Nut, Yoke Plug, Rack Support Spring, Rack Support Yoke And Bushing
Courtesy of HYUNDAI MOTOR CO.
Remove the valve body housing (A) by loosening the two bolts (B).

Fig 9: Identifying Valve Body Housing
Courtesy of HYUNDAI MOTOR CO.
Remove the rack bushing and the rack from the rack housing.
Remove the O-ring (A) from the rack bushing (B).

Fig 10: Removing O-Ring From Rack Bushing (B)
Courtesy of HYUNDAI MOTOR CO.
Remove the oil seal (A) from the rack bushing (B).

Fig 11: Removing Oil Seal From Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Remove the pinion valve assembly (A) from the valve body housing (B) with a soft hammer (C).

Fig 12: Removing Pinion Valve Assembly From Valve Body Housing
Courtesy of HYUNDAI MOTOR CO.
Using the special tool, remove the oil seal and ball bearing from the valve body housing.
Remove the oil seal and O-ring from the rack housing.
CAUTION: Be careful not to damage the pinion valve cylinder inside of the rack housing.
Using the special tool (06573 - 21200, 09555 - 21000), remove the oil seal (A) from the rack housing.
CAUTION: Be careful not to damage the rack cylinder inside of the rack housing.

Fig 13: Removing Oil Seal From Rack Housing
Courtesy of HYUNDAI MOTOR CO.