Power Steering Gear Box: Disassembly

Remove the tie rod end from the tie rod.

Fig 1: Removing Tie Rod End From Tie Rod
Courtesy of KIA MOTORS AMERICA, INC.
Remove the dust cover from the ball joint.

Fig 2: Removing Dust Cover From Ball Joint
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bellows band.

Fig 3: Removing Bellows Band
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bellows clip.
Pull the bellows out toward the tie rod.

Fig 4: Removing Bellows
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Check for rust on the rack when the bellows are replaced.
Remove the feed tubes from the gear housing.
While moving the rack slowly, drain the fluid from the gear housing.
Unstake the tab washer which fixes the tie rod and rack with a chisel.

Fig 5: Removing Tie Rod From Rack (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the tie rod from the rack.
CAUTION: Remove the tie rod from the rack, taking care not to twist the rack.

Fig 6: Removing Tie Rod From Rack (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rack support plug lock nut.

Fig 7: Removing Rack Support Plug Lock Nut
Courtesy of KIA MOTORS AMERICA, INC.
Using the special tool (09565-31300), remove the rack support plug.

Fig 8: Removing Rack Support Plug
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rack support spring, rack support and bushing from the gear box.

Fig 9: Removing Rack Support Spring, Rack Support & Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the end plug self-locking nut.
Detach the dust seal.
Remove the snap ring with a snap ring pliers.

Fig 10: Removing Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.

Fig 11: Removing Pinion & Valve Assembly With Upper Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.

Fig 12: Removing Circlip (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.

Fig 13: Removing Circlip (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not damage the rack.
Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the piston side.

Fig 14: Removing Rack Stopper, Rack Bushing & Rack
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: When the rack has been removed, be sure to replace the housing side oil seal with a new one.
Remove the O-ring from the rack bushing.

Fig 15: Removing O-Ring From Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil seal from the rack bushing.

Fig 16: Removing Oil Seal From Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Drive out the ball bearing using special tool (09517-21400) and hammer.
CAUTION: Do not damage the pinion valve cylinder inside of the gear housing.

Fig 17: Removing Ball Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Drive out the needle bearing and oil seal.

Fig 18: Removing Needle Bearing & Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Use the special tools (09555-21000, 09573-33100) to remove the back washer and oil seal from the gear housing.

Fig 19: Removing Back Washer & Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not damage the rack cylinder inside of the gear housing.