Power Steering Gear Box: Disassembly

Remove the tie rod end (B) from the tie rod (A).

Fig 1: Tie Rod And Tie Rod End
Courtesy of KIA MOTORS AMERICA, INC.
After mounting the tie rod end (A) in a vise, remove the dust cover (B) from the ball joint.

Fig 2: Tie Rod End And Dust Cover
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Remove the bellows band (A).

Fig 3: Bellows Band
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Remove the bellows clip (A).

Fig 4: Removing Bellows Clip
Courtesy of KIA MOTORS AMERICA, INC.
Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
Remove the feed tube (A) from the rack housing.

Fig 5: Identifying Feed Tube
Courtesy of KIA MOTORS AMERICA, INC.
While moving the rack slowly, drain the fluid from the rack housing.
Remove the tie rod (B) from the rack (A).
CAUTION: Remove the tie rod (B) from the rack (A), taking care not to twist the rack.

Fig 6: Identifying Tie Rod And Rack
Courtesy of KIA MOTORS AMERICA, INC.
Remove the yoke plug locking nut (A).

Fig 7: Yoke Plug Locking Nut
Courtesy of KIA MOTORS AMERICA, INC.
Remove the yoke plug (B) with a 14mm socket (A).

Fig 8: Yoke Plug
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Remove the lock nut (D), yoke plug (C), rack support spring (B)and rack support yoke (A) from the gear box.

Fig 9: Identifying Lock Nut, Yoke Plug, Rack Support Spring And Support Yoke
Courtesy of KIA MOTORS AMERICA, INC.
When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.

Fig 10: Removing Circlip
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Remove the rack bushing and rack from the rack housing.
Remove the O-ring (A) from the rack bushing (B).

Fig 11: O-Ring And Rack Bushing
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Remove the oil seal (B) from the rack bushing (A).

Fig 12: Oil Seal And Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the valve body from the valve body housing with a soft hammer.
Using the special tool, remove the oil seal and ball bearing from the valve body housing.
Remove the oil seal and O-ring from the rack housing.
CAUTION: Be careful not to damage the pinion valve cylinder inside of the rack housing.
Using the special tool (09573-21200, 09555-21000), remove the oil seal (A) from the rack housing.
CAUTION: Be careful not to damage the rack cylinder inside of the rack housing.

Fig 13: Identifying Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.