Power Steering Gear Box: Disassembly

Remove the tie rod end from the tie rod.

Fig 1: Removing Tie Rod End
Courtesy of HYUNDAI MOTOR CO.
Remove the dust cover from the ball joint.

Fig 2: Removing Tie Rod End Ball Joint Dust Cover
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
Courtesy of HYUNDAI MOTOR CO.
Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
Remove the feed tube from the gear housing.
While moving the rack slowly, drain the fluid from the gear housing.
Un-stake the tab washer which fixes the tie rod and rack with a chisel.

Fig 5: Un-Staking Tab Washer
Courtesy of HYUNDAI MOTOR CO.
Remove the tie rod from the rack.
CAUTION: Remove the tie rod from the rack, taking care not to twist the rack.

Fig 6: Removing Tie Rod From Steering Gear
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug lock nut.

Fig 7: Removing Yoke Plug Lock Nut
Courtesy of HYUNDAI MOTOR CO.
Using the special tool (09565-31300), remove the yoke plug.

Fig 8: Removing Yoke Plug
Courtesy of HYUNDAI MOTOR CO.
Remove the rack support spring, yoke support and bushing from the gear box.

Fig 9: Removing Rack Support Spring, Yoke Support & Bushing
Courtesy of HYUNDAI MOTOR CO.
Remove the end plug self-locking nut.

Fig 10: Removing End Plug Self-Locking Nut
Courtesy of HYUNDAI MOTOR CO.
Detach the dust seal.
Remove the snap ring with snap ring pliers.
Remove the pinion and valve assembly and the oil seal (upper) using a soft hammer.

Fig 11: Removing Pinion & Valve Assembly
Courtesy of HYUNDAI MOTOR CO.
Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.

Fig 12: Rotating Rack Stopper To Remove Circlip
Courtesy of HYUNDAI MOTOR CO.
When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counter clockwise and remove the circlip.
CAUTION: Do not damage the rack when disassemble.

Fig 13: Removing Circlip
Courtesy of HYUNDAI MOTOR CO.
Remove the rack stopper, rack bushing and rack from the gear housing by moving them toward the piston side.
CAUTION: When the rack has been removed, be sure to replace the housing side oil seal with a new one.

Fig 14: Removing Rack Stopper, Bushing & Rack From Gear Housing
Courtesy of HYUNDAI MOTOR CO.
Remove the O-ring from the rack bushing.

Fig 15: Removing Rack Bushing "O" Ring
Courtesy of HYUNDAI MOTOR CO.
Remove the oil seal from the rack bushing.

Fig 16: Removing Rack Bushing Oil Seal
Courtesy of HYUNDAI MOTOR CO.
Remove out the ball bearing from the gear housing using special tool (09517-21400) and hammer.
CAUTION: Do not damage the pinion valve cylinder inside of the gear housing.

Fig 17: Removing Ball Bearing From Gear Housing
Courtesy of HYUNDAI MOTOR CO.
Remove out the needle bearing and oil seal.

Fig 18: Removing Needle Bearing & Oil Seal From Gear Housing
Courtesy of HYUNDAI MOTOR CO.
Use the special tools (09555-33100) to remove the back washer and oil seal from the gear housing.
CAUTION: Do not damage the rack cylinder inside of the gear housing.

Fig 19: Removing Back Washer & Oil Seal From Gear Housing
Courtesy of HYUNDAI MOTOR CO.