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Power Steering Gear Box: Reassembly

  1. Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack housing.
    Fig 1: Identifying Rack Bar
    G05187103Courtesy of KIA MOTORS AMERICA, INC.
  2. Apply the sealant to the thread of rack bush (A) and then install it to rack housing.

    Tightening torque N.m (kgf.m, lb-ft): 

    100-120 (10.0-12.0, 72-87)

    Fig 2: Applying Sealant To Thread Of Rack Bush
    G05187105Courtesy of KIA MOTORS AMERICA, INC.
  3. Apply the power steering fluid to the bearing (A) and then install it to the valve assembly.
    Fig 3: Identifying Steering Bearing
    G05187106Courtesy of KIA MOTORS AMERICA, INC.
  4. Insert the pinion assembly (A) into the pinion housing. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.
    Fig 4: Inserting Pinion Assembly Into Pinion Housing
    G05187100Courtesy of KIA MOTORS AMERICA, INC.
  5. Install a new oil seal to valve assembly.
    Fig 5: Tapping Oil Seal To Valve Assembly
    G05187108Courtesy of KIA MOTORS AMERICA, INC.
  6. Tighten the pinion lock nut (B).

    Tightening torque N.m (kgf.m, lb-ft): 

    40-50 (4.0-5.0, 29-36)

  7. Apply the sealant to the threads of pinion plug (A) and then install it.

    Tightening torque N.m (kgf.m, lb-ft): 

    45-55 (4.5-5.5, 33-40)

    Fig 6: Applying Sealant To Pinion Plug Threads
    G05187099Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the snap ring (A) to the pinion housing.
    Fig 7: Identifying Snap Ring
    G05187098Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the dust packing (A) and cap (B).
    Fig 8: Identifying Dust Packing And Cap
    G05187111Courtesy of KIA MOTORS AMERICA, INC.
  10. Insert the support yoke (D) and yoke spring (C) into the rack housing.
  11. Apply the sealant to the thread of yoke plug (B) and then install it to the rack housing.
  12. Torque the yoke plug to approx 20 N.m (2 kgf.m, 14 lb-ft) and then loosen it.
  13. Torque the yoke plug to 5-6 N.m (0.5-0.6, 3.6-4.3 lb-ft) again, and then loosen it by approx 35°.
  14. Tighten the lock nut (A) while holding the yoke plug.

    Tightening torque N.m (kgf.m, lb-ft): 

    50-60 (5.0-6.0, 36-43)

    Fig 9: Inserting Support Yoke And Yoke Spring Into Rack Housing
    G05187096Courtesy of KIA MOTORS AMERICA, INC.
  15. Apply the sealant to the thread (A) of tie-rod ball joint and then install it to the rack bar.

    Tightening torque N.m (kgf.m, lb-ft): 

    120-140 (12.0-14.0, 87-101)

    Fig 10: Applying Sealant To Thread Of Tie-Rod Ball Joint
    G05187113Courtesy of KIA MOTORS AMERICA, INC.
  16. Assemble new bellows band (A) to the bellows.
    Fig 11: Identifying Bellows Band
    G05187114Courtesy of KIA MOTORS AMERICA, INC.
  17. Apply the grease to the portion (D) of the tie-rod.
  18. Apply the sealant to the bellows mating surface of the rack housing.
  19. Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).
    Fig 12: Identifying Clip And Band
    G05187115Courtesy of KIA MOTORS AMERICA, INC.
  20. Assemble the lock nut (A) and tie rod end (B) to tie rod.
    Fig 13: Identifying Lock Nut And Tie Rod End
    G05187093Courtesy of KIA MOTORS AMERICA, INC.
  21. Install the feed tubes (A) to steering gear box.
    Fig 14: Identifying Feed Tubes
    G05187092Courtesy of KIA MOTORS AMERICA, INC.
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