Power Steering Gear Box: Reassembly

Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid: PSF-3
Install the oil seal (A) to the specified position in the rack housing.

Fig 1: Installing Oil Seal In Rack Housing
Courtesy of HYUNDAI MOTOR CO.
Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid: PSF-3
Install the oil seal (A) in the rack bushing (B).

Fig 2: Installing Oil Seal In Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
Apply the specified grease to the rack teeth.
Recommended grease

Multipurpose grease SAE J310, NLGI No.2

NOTE: Do not plug the vent hole (A) in the rack with grease.

Fig 3: Identifying Vent Hole In Rack
Courtesy of HYUNDAI MOTOR CO.
Insert the rack into the rack housing and install the rack bushing and rack stopper.
Install the oil seal and the ball bearing in the valve body.
After applying the specified fluid and grease to the pinion valve assembly (A), install it in the rack housing assembly.

Fig 4: Applying Specified Fluid And Grease To Pinion Valve Assembly
Courtesy of HYUNDAI MOTOR CO.
After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly (A) and O-ring in the gear box (B).

Fig 5: Fixing Valve Body Assembly And O-Ring In Gear Box
Courtesy of HYUNDAI MOTOR CO.
Install the tab washer and the tie rod and stake the tab washer (A) end at two points over the tie rod.
NOTE:
1. Align the tab washer pawls with the rack grooves.
2. Always use a new tab washer.
Fig 6: Staking Tab Washer
Courtesy of HYUNDAI MOTOR CO.
Install the bushing (A), rack support yoke (B), rack support spring (C), lock nut (E) and yoke plug (D) in the order shown in Fig 7. Apply semi-drying sealant to the threaded section of the yoke plug before installation.

Fig 7: Identifying Bushing, Rack Support Yoke, Rack Support Spring, Lock Nut & Yoke Plug
Courtesy of HYUNDAI MOTOR CO.
With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nm (150 kg.cm, 11 lb.ft). Loosen the yoke plug approximately from 30° to 60° and tighten the locking nut to the specified torque.
Tightening torque

50~70 Nm (500~700 kgf.cm, 37~52 lbf.ft)

Fig 8: Tightening Locking Nut To Specified Torque
Courtesy of HYUNDAI MOTOR CO.
Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease : Silicone grease

Fig 9: Applying Specified Grease To Bellows Mounting Position Of Tie Rod
Courtesy of HYUNDAI MOTOR CO.
Install the new attaching band to the bellows.
NOTE: When the bellows are installed, a new band must be used.
Install the bellows in position, taking care not to twist it.
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

A: POLY LUB GLY 801K or equivalent

B: SHOWA SUNLIGHT MB2 or equivalent

Dust cover inner side and lip: THREE BOND

Fig 10: Filling Dust Cover Inner Side And Lip With Specified Grease
Courtesy of HYUNDAI MOTOR CO.
Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value

Tie rod free length: 112.2mm

Fig 11: Installing Tie Rods To Specified Value
Courtesy of HYUNDAI MOTOR CO.
Check for total pinion preload.