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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-3

  2. Install the oil seal to the specified position in the rack housing.
    Fig 1: Installing Oil Seal To Specified Rack Housing Position
    G03850131Courtesy of HYUNDAI MOTOR CO.
  3. Apply the specified fluid to the entire surface of the rack bushing oil seal.

    Recommended fluid: PSF-3

  4. Install the oil seal in the rack bushing.
    Fig 2: Installing Oil Seal In Rack Bushing & Applying Specified Fluid To Entire Surface Of Rack Bushing Oil Seal
    G03850132Courtesy of HYUNDAI MOTOR CO.
  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 #2 EP

    NOTE: Do not plug the vent hole in the rack with grease. 
    Fig 3: Locating Vent Hole
    G03850133Courtesy of HYUNDAI MOTOR CO.
  7. Insert the rack into the rack housing and install the rack bushing and rack stopper.
    Fig 4: Inserting Rack Into Rack Housing & Installing Rack Bushing & Rack Stopper
    G03850134Courtesy of HYUNDAI MOTOR CO.
  8. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the circlip while turning the rack stopper.
    CAUTION: The circlip end should not be visible through the notched hole of the rack housing. 
    Fig 5: Installing Circlip While Turning Rack Stopper
    G03850135Courtesy of HYUNDAI MOTOR CO.
  9. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
    Fig 6: Installing Oil Seal & Ball Bearing In Valve Body Housing Using Special Tool
    G03850136Courtesy of HYUNDAI MOTOR CO.
  10. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly.
    Fig 7: View Of Pinion Valve
    G03850137Courtesy of HYUNDAI MOTOR CO.
  11. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly and O-ring in the gear box.
    Fig 8: Fixing Valve Body Assembly And O-Ring In Gear Box
    G03850138Courtesy of HYUNDAI MOTOR CO.
  12. Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.
    Fig 9: Installing Tab Washer, Tie Rod & Staking Tab Washer End At Two Points Over Tie Rod
    G03850139Courtesy of HYUNDAI MOTOR CO.
  13. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.
    Fig 10: Installing Bushing, Rack Support Yoke, Rack Support Spring & Yoke Plug
    G03850140Courtesy of HYUNDAI MOTOR CO.
  14. 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 14mm socket. Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.

    Tightening torque 

    50~70 Nm (500~700 kg.cm, 37~52 lb.ft)

    Fig 11: Attaching Yoke Plug To Rack Housing
    G03850141Courtesy of HYUNDAI MOTOR CO.
  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 12: Applying Specified Grease To Bellows Mounting Position (Fitting Groove) Of Tie Rod
    G03850142Courtesy of HYUNDAI MOTOR CO.
  17. Install the new attaching band to the bellows.
    NOTE: When the bellows are installed, a new band must be used. 
  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 

    1. POLY LUB GLY 801K or equivalent
    2. SHOWA SUNLIGHT MB2 or equivalent

    Dust cover inner side and lip: THREE BOND

    Fig 13: Filling Dust Cover Inner Side & Lip With Specified Grease
    G03850143Courtesy of HYUNDAI MOTOR CO.
  20. Install the tie rods so that the length of the left and right tie rods equals the standard value.

    Standard value 

    Tie rod free length: 204.5mm

    Fig 14: Installing Tie Rods So Length Of Left & Right Tie Rods Equals Standard Value
    G03850144Courtesy of HYUNDAI MOTOR CO.
  21. Check for total pinion preload.
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