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Power Steering Gear Box: Assembly

  1. Install mounting rubber.
  2. Tap mounting bracket on with a plastic hammer.
    Fig 1: Installing Mounting Rubber
    G01078731Courtesy of KIA MOTORS AMERICA, INC.
  3. Apply ATF (Automatic Transmission Fluid) to O-ring and seal ring.
  4. Install O-ring in ring groove of rack.
  5. Install seal ring in groove of rack.
    NOTE: Be careful not to cut or otherwise damage edge of seal ring.
  6. Compress seal ring by hand to fit it to groove.
    Fig 2: Install O-Ring In Ring Groove Of Rack
    G01078732Courtesy of KIA MOTORS AMERICA, INC.
  7. Apply grease to flat surface of housing insert.
    Fig 3: Applying Grease To Flat Surface Of Housing Insert
    G01078733Courtesy of KIA MOTORS AMERICA, INC.
  8. Connect rod seal to grease coated surface of housing insert.
  9. Apply ATF to inside and outside of housing insert and rod seal.
    Fig 4: Applying ATF To Inside And Outside Of Housing Insert And Rod Seal
    G01078734Courtesy of KIA MOTORS AMERICA, INC.
  10. Set housing insert and rod seal on suitable tool.
    Fig 5: Setting Housing Insert And Rod Seal
    G01078735Courtesy of KIA MOTORS AMERICA, INC.
  11. Insert suitable tool from tube side of gear housing.
    Fig 6: Inserting Suitable Tool From Tube Side Of Gear Housing
    G01078736Courtesy of KIA MOTORS AMERICA, INC.
  12. Install and tighten suitable tool nut against tube.
  13. Turn suitable tool shaft in as far as it will go to push in rod seal and housing insert.
  14. Remove suitable tool.
    Fig 7: Installing Rod Seal And Housing Insert
    G01078737Courtesy of KIA MOTORS AMERICA, INC.
  15. Apply grease (lithium base, NLGI No. 2) to friction surface and teeth of rack.
  16. Slide suitable tool over rack and slide it in from tube side of gear housing.
  17. Remove suitable tool.
    Fig 8: Removing Suitable Tool
    G01078738Courtesy of KIA MOTORS AMERICA, INC.
  18. Apply sealant to thread area of rack bushing.
  19. Install rack bushing assembly in rack housing.
  20. Tighten rack bushing as rod seal goes into tube.

    Tightening torque: 65-72 lb.ft (88-98 N.m, 9-10 kg.m) 

    NOTE: Rod seal is pushed to correct position in rack housing by tightening of rack bushing.
    Fig 9: Installing Rack Bushing Assembly In Rack Housing
    G01078739Courtesy of KIA MOTORS AMERICA, INC.
  21. Connect suitable tool to cylinder housing.
  22. Connect a vacuum pump to suitable tool.
  23. Apply 15.7 inHg (400 mmHg)  vacuum.
  24. Verify that vacuum is held for at least 30 seconds. If not, check seal and assembly.
    Fig 10: Testing Seal
    G01078740Courtesy of KIA MOTORS AMERICA, INC.
  25. Secure gear housing in a vise so that lower bearing bore faces upward.
  26. Apply ATF (Automatic Transmission Fluid) to lower bearing, then install in housing.
  27. Press bearing into gear housing with pinion cover. Tighten pinion plug until tightening force suddenly increases.
    Fig 11: Tightening Pinion Plug
    G01078741Courtesy of KIA MOTORS AMERICA, INC.
  28. Apply grease (lithium base, NLGI No. 2) to teeth of pinion shaft.
  29. Apply ATF to seal ring and friction surface of control valve.
  30. Install pinion shaft in housing.
    NOTE:
    1. Be careful not to damage oil seal with pinion teeth.
    2. Be careful not to damage edge of seal ring and control valve.
    Fig 12: Installing Pinion Shaft In Housing
    G01078742Courtesy of KIA MOTORS AMERICA, INC.
  31. Apply ATF to input shaft bearing, and then install it.
    Fig 13: Installing Input Shaft Bearing
    G01078743Courtesy of KIA MOTORS AMERICA, INC.
  32. Apply ATF to oil seal, and fill inside lip with grease (lithium base, NLGI No. 2).
  33. Slide suitable tool over serrations of pinion shaft assembly.
  34. Slide oil seal over suitable tool and position it in housing.
    Fig 14: Positioning Tool In Housing
    G01078744Courtesy of KIA MOTORS AMERICA, INC.
  35. Tap oil seal in with suitable tool until snap ring installation groove in housing is just visible.
    NOTE: Apply uniform force to oil seal when installing.
    Fig 15: Installing Oil Seal
    G01078745Courtesy of KIA MOTORS AMERICA, INC.
  36. Temporarily install tie rod on tube side of rack housing.
  37. Install locknut on pinion shaft assembly and turn it until tie rod contacts tube.
  38. Tighten locknut.

    Tightening torque: 29-36 lb.ft (39-49 N.m, 4.0-5.0 kg.m) 

    Fig 16: Installing Locknut On Pinion Shaft Assembly
    G01078746Courtesy of KIA MOTORS AMERICA, INC.
  39. Apply thread sealant to housing cover threads.
  40. Install housing cover.

    Tightening torque: 33-40 lb.ft (44-54 N.m, 4.5-5.5 kg.m) 

    Fig 17: Installing Housing Cover
    G01078747Courtesy of KIA MOTORS AMERICA, INC.
  41. Stake between rack housing and pinion plug cover at two points with a center punch.
    Fig 18: Staking Between Rack Housing And Pinion Plug Cover
    G01078748Courtesy of KIA MOTORS AMERICA, INC.
  42. Secure gear housing in a vise so that support yoke position faces upward.
  43. Apply grease (lithium base NLGI No. 2) to rack sliding surface of support yoke; then install in housing.
  44. Install support yoke.
    Fig 19: Installing Support Yoke
    G01078749Courtesy of KIA MOTORS AMERICA, INC.
  45. Set rack in center position.
  46. Tighten yoke plug to 7.2 lb.ft (9.8 N.m, 100 kg.cm)  then loosen it.
  47. Tighten again to 3.6 +/- 0.4 lb.ft (4.9 +/- 0.5 N.m, 50 +/- 5 kg.cm)  , and then loosen it 45°
  48. Apply thread sealant to exposed threads of yoke plug.
    Fig 20: Tightening Yoke Plug
    G01078750Courtesy of KIA MOTORS AMERICA, INC.
  49. Install and tighten locknut.

    Tightening torque: 36-43 lb.ft (49-59 N.m, 5.0-6.0 kg.m) 

    Fig 21: Installing And Tighten Locknut
    G01078751Courtesy of KIA MOTORS AMERICA, INC.
  50. Secure rack in a vise.
  51. Install tie rod on rack.

    Tightening torque: 80-94 lb.ft (108-128 N.m, 11-13 kg.m) 

    Fig 22: Installing Tie Rod
    G01078752Courtesy of KIA MOTORS AMERICA, INC.
  52. Tap in a new roll pin.
    Fig 23: Tapping In A New Roll Pin
    G01078753Courtesy of KIA MOTORS AMERICA, INC.
  53. Fill new steering rack boot with specified grease.

    Specified grease (KTSG 06) : Approx. 1.06 oz (30 g) 

  54. Apply a coat of sealant inside of boot contact to rack housing contact area.
  55. Apply grease to inner surface of small end of boot.
  56. Install boot, wrap a new wire around large end of boot two times and then twist it 4 to 4.5 times. Bend twisted part toward mounting bracket.
    NOTE: Be careful not to break boot wire.
  57. Install spring clip on small end of boot.
    Fig 24: Installing Spring Clip On Small End Of Boot
    G01078754Courtesy of KIA MOTORS AMERICA, INC.
  58. Align with mark made before disassembly, and then tighten nut.
    Fig 25: Aligning Tie Rod End Mark
    G01078755Courtesy of KIA MOTORS AMERICA, INC.
  59. Secure mounting bracket in a vise so that oil pipe connections face upward.
    Fig 26: Installing Oil Pipes
    G01078756Courtesy of KIA MOTORS AMERICA, INC.
  60. Install oil pipe bracket to oil pipes and steering gear housing and tighten two bracket bolts and nuts.

    Tightening torque: 29-36 lb.ft (39-49 N.m, 4.0-5.0 kg.m) 

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