Power Steering Gear Box: Reassembly

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

Fig 1: Identifying Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid: PSF-III
Install the oil seal (A) in the rack bushing (B).

Fig 2: Identifying Oil Seal And Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
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 J310a 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 KIA MOTORS AMERICA, INC.
Insert the rack (A) into the rack housing (B) and install the rack bushing (C).

Fig 4: Identifying Rack, Rack Housing And Rack Bushing
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Using a special tool, install the oil seal and the ball bearing in the valve body housing.
After applying the specified fluid and grease to the pinion valve assembly (A), install it in the rack housing assembly.

Fig 5: Identifying Valve Body
Courtesy of KIA MOTORS AMERICA, INC.
Install the rack support yoke (A), rack support spring (B), yoke plug (C) and lock nut (D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.

Fig 6: Identifying Lock Nut, Yoke Plug, Rack Support Spring And Support Yoke
Courtesy of KIA MOTORS AMERICA, INC.
Install the locking nut with a specified torque, after adjusting the rack support yoke as following instruction.
1. Place the rack in the center position.
2. Tighten the yoke plug with a specified torque.
  Specified torque N.m (kgf.m, lb-ft) :
  
  Manual 9-11 (0.9-1.1,6.5-7.9), Power 20 (2,14.5)
3. Reciprocate the rack slowly 5 times.
4. Place the rack in the center position again, and then loosen the yoke plug.
5. Tighten the yoke with a specified torque, and turn at a certain degree in reverse.
  Specified torque N.m (kgf.m, lb-ft) :
  
  Manual 4.5-6.5 (0.45-0.65,3.25-4.70),
  
  Power 5-6 (0.5-0.6,3.62-4.34)
  
  Reverse angle :
  
  25° ±5° (Manual), 35° (Power)
6. Tighten the yoke lock nut without moving yoke plug.
  Specified torque N.m (kgf.m, lb-ft) :
  
  Manual 40-50 (4-5,28.9-36.2),
  
  Power 50-60 (5-6,36.2-43.4)
  
  Fig 7: Identifying Yoke Lock Nut
  Courtesy of KIA MOTORS AMERICA, INC.
Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive.
Tightening torque :

25-30 N.m (2.5-3 kgf.m, 18.0-21.7 lb-ft)

Fig 8: Identifying Feed Tube
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Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease: Silicone grease

Fig 9: Identifying Mounting Position (Fitting Groove) Of Tie Rod
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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: Identifying Grease Applying Area Of Dust Cover Inner Side And Lip
Courtesy of KIA MOTORS AMERICA, INC.
Install temporarily the tie rod (A) to the tie rod end (B).

Fig 11: Identifying Tie Rod And Tie Rod End
Courtesy of KIA MOTORS AMERICA, INC.
Check for total pinion preload.
Total pinion preload :

0.6-1.3 N.m (6-13 kgf.cm, 0.4-1.0 lb-ft)

Fig 12: Checking Pinion Preload
Courtesy of KIA MOTORS AMERICA, INC.