Repair Procedure: Reassembly

Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
Install the backup washer and oil seal (A) to the specified position in the rack housing.

Fig 1: Installing Backup Washer & Oil Seal
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Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-3
Install the oil seal (A) in the rack bushing (B).

Fig 2: Installing Oil Seal
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
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Insert the rack (A) into the rack housing (B) and install the rack bushing (C).

Fig 4: Rack, Housing & Bushing
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Push in the rack stopper (A) until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Then, install the circlip while turning the rack stopper.
CAUTION: The circlip should not be visible through the notched hole of the rack housing.

Fig 5: Identifying Rack Stopper
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Using special Tool (09432-21600), install the oil seal and the ball bearing in the valve body (A).

Fig 6: Valve Body
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After applying the specified fluid and grease to the pinion valve assembly (A), install it in the rack housing assembly.

Fig 7: Installing Pinion Valve Assembly
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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 8: Valve Body Assembly & Gear Box
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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 9: Rack Support Yoke, Rack Support Spring, Yoke Plug & Lock Nut
Courtesy of KIA MOTORS AMERICA, INC.
With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 12 Nm (120 kg.cm, 8.9 lb.ft), with a 14 mm socket (A). Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.
Tightening Torque Nm (kgf.m, lb-ft) : 50 ~ 70 (5 ~ 7, 37 ~ 52)

Fig 10: Tightening Yoke Plug
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Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive.

Fig 11: Tightening 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 12: Bellows Mounting Position
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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
1. POLY LUB GLY 801K or equivalent
2. SHOWA SUNLIGHT MB2 or equivalent
  Dust cover inner side and lip : THREE BOND
  
  Fig 13: Grease Areas
  Courtesy of KIA MOTORS AMERICA, INC.
Install the tie rod end (B) to the tie rod (A).

Fig 14: Installing Tie Rod End
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