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Power Steering Gear Box: Assembly

  1. Install the grommets and mounting brackets.
    NOTE: Ensure the lip spring of the seal points toward the installation tool.
  2. Use the Rack Oil Seal Replacer and install a new seal.
    Fig 1: Installing A New Rack Seal
    G01106099Courtesy of KIA MOTORS AMERICA, INC.
  3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.
    Fig 2: Installing A New O-Ring
    G01106100Courtesy of KIA MOTORS AMERICA, INC.
  4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on the rack.
    Fig 3: Installing Short Rack Seal Protector
    G01106101Courtesy of KIA MOTORS AMERICA, INC.
  5. Place the Rack Oil Seal Protector over the rack as shown in illustration. Install the rack, with the rack oil seal protector, into the steering gear housing. Remove the rack oil seal protector.
    Fig 4: Installing Rack Oil Seal Protector
    G01106102Courtesy of KIA MOTORS AMERICA, INC.
  6. Use the Pinion Bearing Replacer to install the lower pinion bearing.
    Fig 5: Installing The Lower Pinion Bearing
    G01106103Courtesy of KIA MOTORS AMERICA, INC.
  7. If the valve housing, steering gear housing, or pinion and control valve assembly have been replaced, perform the valve housing adjustment procedure. If none of these components have been replaced, install any shims that were removed.
  8. Use the Seal Installation Set to install a new Teflon R pinion seals on the pinion and control valve assembly.
    1. Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the valve assembly to the first seal groove. Push the seal into the groove by using the Pusher.
      Fig 6: Installing The First Seal
      G01106104Courtesy of KIA MOTORS AMERICA, INC.
    2. Size the seal by sliding the large end of Sizer over the seal.
    3. Before installing the second seal, place one Spacer on the valve assembly. Install and size the seal by using the Mandrel and the Pusher.
    4. Before installing the third seal, place two Spacers, on the valve assembly. Make sure both spacers are positioned on the valve assembly as the one shown in illustration. Install and size the third seal.
      Fig 7: Installing And Sizing The Third Seal
      G01106105Courtesy of KIA MOTORS AMERICA, INC.
    5. To install the fourth seal, turn the second spacer around so the small ends of the spacers are facing each other on the valve assembly.
  9. Insert the pinion and control valve assembly into the valve housing making sure that it seats properly.
  10. Install a new O-ring.
  11. Position the valve housing and the pinion and control valve assembly, then install the valve housing bolts. Tighten the valve housing bolts to 15~19 lb. ft. (21~26 N.m, 2.1~2.6 kg.m).
  12. Use the Pinion Seal Replacer/Torque Adapter to install the bearing.
  13. Use the Pinion Seal Replacer/Torque Adapter to install the seal.
    Fig 8: Installing Bearing And Seal
    G01106106Courtesy of KIA MOTORS AMERICA, INC.
  14. Install the support yoke.
  15. Install the spring.
  16. Apply a sealant to the yoke plug threads. Install the yoke plug and tighten it to the specified torque.

    Tightening torque :

    14.5 lb. ft. (19.6 N.m, 2 kg.m)

    Fig 9: Installing The Yoke Plug And Tightening It To The Specified Torque
    G01106107Courtesy of KIA MOTORS AMERICA, INC.
  17. Loosen the support yoke.
  18. Tighten the yoke plug with torque wrench to 43 lb. in (4.9 N.m, 50 kg.cm) three times, then return it 67.5 degrees.
    Fig 10: Tightening The Yoke Plug
    G01106108Courtesy of KIA MOTORS AMERICA, INC.
  19. Measure the pinion torque with the SST and spring scale.

    Standard :

    Center of rack +/- 90°

    6.9~11.3 lb. in (0.8~1.3 N.m, 8~13 kg.cm)

    Scale reading : 800~1,300 kg (28.2~45.9 oz)

    Fig 11: Measuring The Pinion Torque
    G01106109Courtesy of KIA MOTORS AMERICA, INC.
  20. If not within the specification, repeat previous steps.
  21. Use the Yoke Lock Nut Wrench to install the lock nut and tighten to 29~36 lb. ft. (39~49 N.m, 4~5 kg.m).
    Fig 12: Installing The Lock Nut
    G01106110Courtesy of KIA MOTORS AMERICA, INC.
  22. Install the tie rods.
  23. Align the washer with the rack groove, and then crimp the washer.
  24. Install the boots.
  25. Install the boot wires.
  26. Install the boot clips.
  27. Install the left tie rod end and lock nut.
  28. Install the oil pipes.
    Fig 13: Installing The Oil Pipes
    G01106111Courtesy of KIA MOTORS AMERICA, INC.
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