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Power Steering Gear Box: Reassembly

  1. Apply the specified fluid to the entire surface of the rack oil seal.

    Recommended fluid : PSF-III

  2. Install the backup washer and oil seal (A) to the specified position in the rack housing.
    Fig 1: Installing Backup Washer & Oil Seal Into Rack Housing
    G00333678Courtesy of KIA MOTORS AMERICA, INC.
  3. Apply the specified fluid to the entire surface of the rack bushing oil seal.

    Recommended fluid : PSF-III

  4. Install the oil seal (A) in the rack bushing (B).
    Fig 2: Installing Oil Seal Into Rack Bushing
    G00333679Courtesy of KIA MOTORS AMERICA, INC.
  5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
  6. 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
    G00333680Courtesy of KIA MOTORS AMERICA, INC.
  7. Insert the rack (A) into the rack housing (B) and install the rack bushing (C) and rack stopper (D).
    Fig 4: Installing Rack, Rack Bushing & Rack Stopper
    G00333681Courtesy of KIA MOTORS AMERICA, INC.
    8. CAUTION: The clip (A) end should not be visible through the notched hole of the rack housing.
    Fig 5: Identifying Circlip Position
    G00333682Courtesy of KIA MOTORS AMERICA, INC.
  8. Push in the rack stopper until the clip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the clip (A) while turning the rack stopper.
  9. Install the oil seal and the ball bearing in the valve body (A).
    Fig 6: Installing Oil Seal & Ball Bearing Into Valve Body
    G00333683Courtesy of KIA MOTORS AMERICA, INC.
  10. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly. See Figure.
  11. 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 7: Installing Valve Body Assembly To Gear Box
    G00333685Courtesy of KIA MOTORS AMERICA, INC.
  12. 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 8: Installing Tab Washer
    G00333686Courtesy of KIA MOTORS AMERICA, INC.
  13. Install the bushing (A), rack support yoke (B), rack support spring (C), lock nut (E) and yoke plug (D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.
    Fig 9: Identifying Correct Installation Order Of Bushing, Rack Support Yoke, Rack Support Spring, Yoke Plug & Lock Nut
    G00333687Courtesy of KIA MOTORS AMERICA, INC.
  14. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 N.m (150 kg.cm, 11 lb.ft), using a 14 mm socket. Loosen the yoke plug approximately from 30° to 60° and tighten the locking nut to the specified torque.

    Tightening torque

    50-70 N.m (500-700 kg.cm, 36-51 lb.ft)

  15. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
  16. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.

    Recommended grease: Silicone grease

    Fig 10: Identifying Bellows Fitting Groove
    G00333689Courtesy of KIA MOTORS AMERICA, INC.
    17. NOTE: When the bellows are installed, a new band must be used.
  17. Install the new attaching band to the bellows.
  18. Install the bellows in position, taking care not to twist it.
  19. 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 11: Identifying Lubrication Points
    G00333690Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the tie rods so that the length of the left and right tie rods equal the standard value.

    Standard value

    Tie rod free length (A) : 203.6 mm (8 in.)

    Fig 12: Identifying Tie Rod Free Length
    G00333691Courtesy of KIA MOTORS AMERICA, INC.
  21. Check for total pinion preload.
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