Power Steering Gear Box: Reassembly

Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid: PSF-3
Install the oil seal to the specified position in the rack housing.

Fig 1: Installing Oil Seal To Rack Housing
Courtesy of HYUNDAI MOTOR CO.
Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid: PSF-3
Install the oil seal in the rack bushing.

Fig 2: Installing Oil Seal In Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
Apply the specified grease to the rack teeth.
Recommended grease:

Multipurpose grease SAE J310a, NLGI #2 EP

NOTE: Do not plug the vent hole in the rack with grease.

Fig 3: Identifying Rack
Courtesy of HYUNDAI MOTOR CO.
Insert the rack into the rack housing and push in the rack bushing until it is aligned with the notched hole of the rack housing, then install it.

Fig 4: Inserting Rack Into Rack Housing And Pushing In Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Using a special tool, install the oil seal and the ball bearing in the valve body housing.
After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly.

Fig 5: Identifying Pinion Valve Assembly
Courtesy of HYUNDAI MOTOR CO.
After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly and O-ring in the gear box.

Fig 6: Installing Valve Body Assembly To Gear Box
Courtesy of HYUNDAI MOTOR CO.
Install the tie rod and punch on a point over the tie rod with a chisel.

Fig 7: Installing Tie Rod Using Punch Over Tie Rod With A Chisel
Courtesy of HYUNDAI MOTOR CO.
Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.

Fig 8: Installing Bushing, Rack Support Yoke, Rack Support Spring & Yoke Plug
Courtesy of HYUNDAI MOTOR CO.
With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 12 Nm (120 kg.cm, 8.9 lb.ft), with a 14mm socket. Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.
Tightening torque

50~70 Nm (500~700 kg.cm, 37~52 lb.ft)
Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease: Silicone grease
Install the new attaching band to the bellows.
NOTE: When the bellows are installed, a new band must be used.
Install the bellows in position, taking care not to twist it.

Fig 9: Installing Bellows
Courtesy of HYUNDAI MOTOR CO.
Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.
Recommended grease

A: POLY LUB GLY 801K or equivalent

B: SHOWA SUNLIGHT MB2 or equivalent

Dust cover inner side and lip: THREE BOND

Fig 10: Filling Dust Cover Inner Side & Lip With Grease
Courtesy of HYUNDAI MOTOR CO.
Install the tie rod to the tie rod end.

Fig 11: Installing Tie Rod To Tie Rod End
Courtesy of HYUNDAI MOTOR CO.
Check for total pinion preload.

Fig 12: Checking For Total Pinion Preload

Courtesy of HYUNDAI MOTOR CO.