Power 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
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 rack housing.
While moving the rack slowly, drain the fluid from the rack housing.
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 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 Rack
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug locking nut.

Fig 7: Removing Yoke Plug Locking Nut
Courtesy of HYUNDAI MOTOR CO.
Remove the yoke plug with a 14mm socket.

Fig 8: Removing Yoke Plug With 14mm Socket
Courtesy of HYUNDAI MOTOR CO.
Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.

Fig 9: Removing Lock Nut, Yoke Plug, Rack Support Spring, Rack Support Yoke & Bushing From Gear Box
Courtesy of HYUNDAI MOTOR CO.
Remove the valve body housing by loosening the two bolts.

Fig 10: Removing Valve Body Housing By Loosening Two Bolts
Courtesy of HYUNDAI MOTOR CO.
Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.

Fig 11: Turning Rack Stopper Clockwise Until End Of Circlip Comes Out Of Slot In Rack Housing
Courtesy of HYUNDAI MOTOR CO.
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 12: Turning Rack Stopper Counterclockwise & Removing Circlip
Courtesy of HYUNDAI MOTOR CO.
Remove the rack stopper, rack bushing and rack from the rack housing.
Remove the O-ring from the rack bushing.

Fig 13: Removing O-Ring From Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Remove the oil seal from the rack bushing.

Fig 14: Removing Oil Seal From Rack Bushing
Courtesy of HYUNDAI MOTOR CO.
Remove the valve body from the valve body housing with a soft hammer.

Fig 15: Removing Valve Body From Valve Body Housing With A Soft Hammer
Courtesy of HYUNDAI MOTOR CO.
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 bore of the rack housing.
Using the special tool, remove the oil seal from the rack housing.
CAUTION: Be careful not to damage the rack cylinder bore of the rack housing.

Fig 16: Using Special Tool To Remove Oil Seal From Rack Housing
Courtesy of HYUNDAI MOTOR CO.