Manual Steering Gear Box: Reassembly

Apply the specified grease to the rack, insert the rack into the gear housing, and then insert the pinion into the gear housing.
- Make sure that the rack is inserted into the gear housing from the left side.
- When inserting the pinion into the gear housing, the pinion gear should be in mesh with the rack gear.
- Wipe off excessive grease.
Fig 1: Inserting Rack Into Gear Housing
Courtesy of HYUNDAI MOTOR CO.
Prior to oil seal installation in the gear box, apply grease to the surface of the oil seal.
NOTE: Be sure to use a new oil seal.
Install the rack support yoke, rack support spring, yoke plug, and lock nut to the pinion gear box.

Fig 2: Installing Rack Support Yoke, Rack Support Spring, Yoke Plug & Lock Nut To Pinion Gear Box
Courtesy of HYUNDAI MOTOR CO.
Tighten the yoke plug to 11 Nm (112 kg.cm, 8 lb.ft) and then back off 30°~60°. Secure the yoke plug with the lock nut.
CAUTION:
1. Adjust the yoke plug with the rack in the neutral position.
2. Apply a sealer between the lock nut and the housing.
Fig 3: Securing Yoke Plug With Lock Nut
Courtesy of HYUNDAI MOTOR CO.
After installing the tie rod to the rack, punch on a point over the tie rod with a chisel.

Fig 4: Punching On A Point Over Tie Rod With A Chisel
Courtesy of HYUNDAI MOTOR CO.
Install the bellows in position and fix it with the band and clip.

Fig 5: Installing Bellows In Position & Fixing It With The Band & Clip
Courtesy of HYUNDAI MOTOR CO.
Mount tie rod end in a vise and install the dust cover to the tie rod end.

Fig 6: Installing Tie Rod Dust Cover
Courtesy of HYUNDAI MOTOR CO.
Install the tie rod to the tie rod end.

Fig 7: Installing Tie Rod To Tie Rod End

Courtesy of HYUNDAI MOTOR CO.