Power Steering Gear Box: Assembly

Apply the specified fluid to the entire surface of the oil seal and gear housing.
Recommended fluid : Power steering fluid (PSF-3)
Using the special tools (09555-21000, 09573-21000, 09573-33000, 09573-33100), install the backup washer and oil seal to the specified position in the gear housing.

Fig 1: Installing Backup Washer & Oil Seal In Gear Housing
Courtesy of KIA MOTORS AMERICA, INC.
Apply the specified grease to the entire surface of the needle bearing.
Recommended grease : Multipurpose grease SAE H310a, NLGI No.2
Install the needle bearing in the gear housing using special tool (09222-21100).

Fig 2: Installing Needle Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install in the gear housing.
CAUTION:
1. Note the direction of the oil seal.
2. Use a new oil seal.
Fig 3: Installing Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : Power steering fluid (PSF-3)
Install the oil seal on the rack bushing.
Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool 09431-11000).

Fig 4: Installing O-Ring
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Apply the specified grease to the rack teeth and wrap with vinyl tape.
Recommended grease : Multipurpose grease SAE J310a, NLGI grade # 2 EP

CAUTION: Do not plug the vent hole in the rack with grease. If the vent hole is plugged with grease, damage to rack unit will occur.

Fig 5: Identifying Vent Hole In Rack
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Insert the rack into the gear housing.
Install the rack bushing and rack stopper.

Fig 6: Installing Rack Bushing & Rack Stopper
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Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing and then 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 7: Installing Circlip
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Apply the specified fluid and grease to the pinion valve assembly and install to the gear housing assembly.
Recommended fluid : Power steering fluid (PSF-3)

Recommended grease : Multipurpose grease

SAE J310A, NLGI Grade # 2 EP

Fig 8: Installing Pinion Valve Assembly
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Install the ball bearing using special tool (09222-21100).

Fig 9: Installing Ball Bearing
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Install the pinion and valve assembly to the valve housing.
Install the oil seal using the special tool (09432-21601).

Fig 10: Installing Oil Seal
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Install the snap ring with snap ring pliers.
With the pinion turned all the way clockwise, tighten the self-locking nut.
Tightening torque : 45-50 Nm (450-500 kg. cm, 33-36 lb. ft.)

CAUTION: Always replace the self-locking nut with a new one.

Fig 11: Installing Self-Locking Nut
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Apply semi-drying sealant to the threaded section of the end plug and tighten to the specified torque.
Tightening torque : 45-55 Nm (450-550 kg. cm, 33-40 lb. ft.)

Fig 12: Installing End Plug
Courtesy of KIA MOTORS AMERICA, INC.
Stake the end plug at two points on its circumference with a punch.
Install the tab washer and then the tie rod and peen the tab washer end at two points to the tie rod.
CAUTION:
1. Align the tab washer pawls with the rack grooves.
2. Use a new tab washer.
Fig 13: Installing Tab Washer & Tie Rod
Courtesy of KIA MOTORS AMERICA, INC.
Install the bushing, rack support, rack support spring and rack support cover in the order shown in illustration. Apply thread sealant to the threaded section of the rack support cover before installation.

Fig 14: Installing Bushing, Rack Support, Rack Support Spring & Rack Support Cover
Courtesy of KIA MOTORS AMERICA, INC.
With the rack placed at the center position, attach the rack support plug to the gear housing. Temporary tighten yoke plug with 20 Nm (200 kg. cm, 15 lb. ft.) and return. Tighten yoke plug with 5-6 Nm (50-60 kg. cm, 3.6-4.3 lb. ft.) and return 35° and adjust torque to the standard value.
Total pinion torque [Standard value] : 25-35 Nm (250-350 kg. cm, 18-25 lb. ft.)

Fig 15: Installing Rack Support Plug
Courtesy of KIA MOTORS AMERICA, INC.
After adjusting, lock rack support plug with lock nut.
NOTE: When it cannot be adjusted within the specified return angle, check rack support plug components or replace.
Tighten the feed tube to the specified torque and install the mount rubber using adhesive.
Apply the specified grease to the bellows fitting position (fitting groove) of the tie rod.
Recommended grease : Multipurpose grease

SAE J3120a, NLGI grease # 2 EP

Fig 16: Installing Bellows
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Install the new attaching band to the bellows.
CAUTION: Whenever the bellows are installed, a new band must be used.
Install the bellows, taking care not to twist it.
Fill the dust cover inner side and lip with the specified multipurpose grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.
Recommended grease : Multipurpose grease

SAE J310a, NLGI grade # 2 EP

Fig 17: Installing Dust Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the tie rods so that the length of the left and right tie rods will be equal to the standard value.
Tie rod free length [Standard value]: 43 mm (1.69 in.)

Fig 18: Installing Tie Rod Ends

Courtesy of KIA MOTORS AMERICA, INC.