Repair Procedures: Disassembly

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

Fig 1: Removing Tie Rod End
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After mounting the tie rod end (A) in a vise, remove the dust cover (B) from the ball joint.

Fig 2: Removing Dust Cover
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Remove the bellows band (A).

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

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.
Remove the feed tube (A) from the rack housing.

Fig 5: Removing Feed Tube From Rack Housing
Courtesy of KIA MOTORS AMERICA, INC.
While moving the rack slowly, drain the fluid from the rack housing.
Unstake the tab washer (A) which fixes the tie rod (B) and rack (C) with a chisel.

Fig 6: Unstaking Tab Washer
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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 7: Removing Tie Rod From Rack
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Remove the yoke plug locking nut (A).

Fig 8: Removing Yoke Plug Locking Nut
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Remove the yoke plug (B) with a 14 mm socket (A).

Fig 9: Removing 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 10: Lock Nut, Yoke Plug, Rack Support Spring & Rack Support Yoke
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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 11: Turning Rack Stopper
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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 12: Removing O-Ring From Rack Bushing
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Remove the oil seal (B) from the rack bushing (A).

Fig 13: Removing Oil Seal From Rack Bushing
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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 14: Removing Oil Seal From Rack Housing

Courtesy of KIA MOTORS AMERICA, INC.