Repair Procedures: Reassembly

Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-4
Install the backup washer and oil seal (A) to the specified position in the rack housing.

Fig 1: Installing Backup Washer And Oil Seal
Courtesy of HYUNDAI MOTOR CO.
Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-4
Install the oil seal (A) in the rack bushing (B).

Fig 2: Installing Oil Seal In Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
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
Courtesy of HYUNDAI MOTOR CO.
Insert the rack (A) into the rack housing (B) and install the rack bushing (C).

Fig 4: Identifying Rack, Rack Housing And Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
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
Courtesy of HYUNDAI MOTOR CO.
Using special Tool (09432-21600), install the oil seal and the ball bearing in the valve body (A).

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

Fig 7: Installing Rack Housing Assembly
Courtesy of HYUNDAI MOTOR CO.
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: Identifying Valve Body Assembly With O-Ring In Gear Box
Courtesy of HYUNDAI MOTOR CO.
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: Identifying Rack Support Yoke, Rack Support Spring, Yoke Plug And Lock Nut
Courtesy of HYUNDAI MOTOR CO.
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 (A). Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.
Tightening torque:

50 ~ 70N.m (5 ~ 7kgf.m, 37 ~ 52lb-ft)

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

Fig 11: Tightening Feed Tube
Courtesy of HYUNDAI MOTOR CO.
Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease : Silicone grease

Fig 12: Identifying Grease Applying Areas
Courtesy of HYUNDAI MOTOR CO.
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: Identifying Grease Applying Areas On Dust Cover Inner Side And Lip
Courtesy of HYUNDAI MOTOR CO.
Install the tie rod end (B) to the tie rod (A).

Fig 14: Installing Tie Rod End To Tie Rod
Courtesy of HYUNDAI MOTOR CO.