Power Steering Gear Box: Disassembly

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

Fig 1: Identifying Tie Rod End And Tie Rod
Courtesy of KIA MOTORS AMERICA, INC.
Remove the dust cover (B) from the ball joint (A).

Fig 2: Identifying Dust Cover And Ball Joint
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bellows band (A).

Fig 3: Identifying Bellows Band
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bellows clip (A).

Fig 4: Identifying Bellows Clip
Courtesy of KIA MOTORS AMERICA, INC.
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: Identifying Feed Tube
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 Washer With Chisel
Courtesy of KIA MOTORS AMERICA, INC.
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: Identifying Tie Rod And Rack
Courtesy of KIA MOTORS AMERICA, INC.
Remove the yoke plug locking nut (A).

Fig 8: Identifying Yoke Plug Locking Nut
Courtesy of KIA MOTORS AMERICA, INC.
Remove the yoke plug (B) with a 14mm socket (A).

Fig 9: Removing Yoke Plug
Courtesy of KIA MOTORS AMERICA, INC.
Remove the lock nut (D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box.

Fig 10: Identifying Lock Nut, Yoke Plug, Rack Support Spring And Rack Support Yoke
Courtesy of KIA MOTORS AMERICA, INC.
When the end of the circlip comes out of the notched-hole of the housing rack cylinder, turn the rack stopper (A) clockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.

Fig 11: Turning Rack Stopper - Clockwise
Courtesy of KIA MOTORS AMERICA, INC.
When the end of the circlip comes out of the notched hole (A) of the housing rack cylinder, turn the rack stopper (B) counterclockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.

Fig 12: Turning Rack Stopper - Counterclockwise
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rack bushing and rack from the rack housing.
Remove the O-ring (A) from the rack bushing (B).

Fig 13: Identifying O-Ring And Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil seal (B) from the rack bushing (A).

Fig 14: Identifying Oil Seal And Rack Bushing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the valve body (A) from the valve body housing (B) with a soft hammer.

Fig 15: Identifying Valve Body And Valve Body Housing
Courtesy of KIA MOTORS AMERICA, INC.
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 (09573-33100, 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 16: Identifying Special Tool (09573-33100, 09555-21000)
Courtesy of KIA MOTORS AMERICA, INC.