Repair Procedures: Disassembly

Remove the feed tube.

Fig 1: Locating Feed Tube
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Remove the tie rod end from the tie rod.

Fig 2: Removing Tie Rod End
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Remove the dust cover from the ball joint.

Fig 3: Removing Dust Cover
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Remove the bellows band.

Fig 4: Removing Bellows Band
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Remove the bellows clip. Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
Remove the feed tube from the rack housing.

Fig 5: Removing Feed Tube
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While moving the rack slowly, drain the fluid from the rack housing.
Unstake the tab washer which fixes the tie rod and rack with a chisel.

Fig 6: Unstaking Tie Rod Tab Washer
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Remove the tie rod from the rack.
CAUTION: Remove the tie rod from the rack, taking care not to twist the rack.

Fig 7: Removing Tie Rod
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Remove the yoke plug lock nut.

Fig 8: Removing Yoke Plug Lock Nut
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Using the special tool (09565-31300), remove the yoke plug.

Fig 9: Removing Yoke Plug Using Special Tool (09565-31300)
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Remove the rack support spring, yoke support and bushing from the gear box.

Fig 10: Identifying Rack Support Spring, Yoke Support And Bushing
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Remove the end plug and self-locking nut.

Fig 11: Identifying End Plug And Self-Locking Nut
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Detach the dust seal.
Remove the snap ring with snap ring pliers.
Remove bolts mounting the valve assembly to the rack housing.
Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.

Fig 12: Removing Pinion And Valve Assembly
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Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.

Fig 13: Turning Rack Stopper
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When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counter clockwise and remove the circlip.
CAUTION: Do not damage the rack when disassembling.

Fig 14: Removing Circlip
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Remove the rack stopper, rack bushing and rack from the rack housing by moving it toward the piston side.
CAUTION: When the rack has been removed, be sure to replace the housing side oil seal with a new one.

Fig 15: Removing Rack Stopper, Rack Bushing And Rack
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Remove the O-ring from the rack bushing.

Fig 16: Removing O-Ring From Rack Bushing
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Remove the oil seal from the rack bushing.

Fig 17: Removing Oil Seal From Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.