Manual Steering Gear Box: Disassembly

Remove the tie rod end from the tie rod.

Fig 1: Removing Tie Rod End From Tie Rod
Courtesy of HYUNDAI MOTOR CO.
After mounting the tie rod end in a vise, remove the dust cover from the ball joint.

Fig 2: Removing Dust Cover From Ball Joint
Courtesy of HYUNDAI MOTOR CO.
Remove the bellows band.

Fig 3: Removing Bellows Band
Courtesy of HYUNDAI MOTOR CO.
Remove the bellows clip.

Fig 4: Removing Bellows Clip
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Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
Unstake the tab washer which fixes the tie rod and rack with a chisel.

Fig 5: Unstaking Tab Washer
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug lock nut.

Fig 6: Removing Yoke Plug Lock Nut
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug with a 14mm socket.

Fig 7: Removing Yoke Plug
Courtesy of HYUNDAI MOTOR CO.
Remove the lock nut, yoke plug rack support spring, rack support yoke and bushing.

Fig 8: Removing Lock Nut, Yoke Plug Rack Support Spring & Rack Support Yoke & Bushing
Courtesy of HYUNDAI MOTOR CO.
Move the rack completely toward the housing and mount the rack tooth portion in a brass plate of a vise. At the state of step 11, loosen the tie rod ball joint, then remove the tie rod tie rod assembly from the rack.

Fig 9: Loosening Tie Rod Ball Joint
Courtesy of HYUNDAI MOTOR CO.
Remove the rack from the gear housing.

CAUTION: Remove the rack toward the left side of the vehicle so as not to damage the bushing by the rack teeth.

Fig 10: Removing Rack From Gear Housing

Courtesy of HYUNDAI MOTOR CO.