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Home >> Hyundai >> 2004 >> XG350 Base >> Repair and Diagnosis >> Steering >> Power Steering >> Steering System >> Mechanical Power Steering System >> Power Steering Gear Box >> Assembly
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Power Steering Gear Box: Assembly

  1. Apply the specified fluid to the entire surface of the oil seal and gear housing.

    Recommended fluid 

    Power steering fluid (PSF-3)

  2. Using the special tools (09555-21000, 09573-21000, 09573-33000, 09573-33100), install the backup washer and oil seal to the specified positioning the gear housing.
  3. Apply the specified grease to the entire surface of the needle bearing.

    Recommended grease 

    Multipurpose grease SAE J310a, NLGI No. 2

    Fig 1: Identifying Grease Application Locations
    G00721916Courtesy of HYUNDAI MOTOR CO.
  4. Install the needle bearing in the gear housing using the special tool (09222-21100).
    Fig 2: Installing Needle Bearing To Gear Housing
    G00721917Courtesy of HYUNDAI MOTOR CO.
  5. Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install in the gear housing.
    CAUTION:
    1. Note the direction of the oil seal.
    2. Use a new oil seal.
    Fig 3: Installing Oil Seal To Gear Housing
    G00721918Courtesy of HYUNDAI MOTOR CO.
  6. Apply the specified fluid to the entire surface of the rack bushing oil seal.

    Recommended fluid 

    Power steering fluid (PSF-3)

  7. Install the oil seal on the rack bushing.
  8. Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool (09431-11000).
    Fig 4: Installing Rack Bushing Seal & Rack Bushing "O" Ring
    G00721919Courtesy of HYUNDAI MOTOR CO.
  9. Apply the specified grease to the rack teeth.

    Recommended grease 

    Multipurpose grease SAE J310a, NLGI grade #2 EP

    CAUTION: Do not plug the vent hole in the rack with grease.
    Fig 5: Identifying Rack Gear Vent Hole
    G00721920Courtesy of HYUNDAI MOTOR CO.
  10. Insert the rack into the gear housing. Install the rack bushing and rack stopper.
    Fig 6: Installing Rack Gear, Rack Bushing & Rack Stopper
    G00721921Courtesy of HYUNDAI MOTOR CO.
  11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing and then install the circlip while turning the rack stopper.
    CAUTION: The circlip end should not be visible through the notched hole of the rack housing.
    Fig 7: Identifying Correct Positioning Of Circlip
    G00721922Courtesy of HYUNDAI MOTOR CO.
  12. Apply the specified fluid and grease to the pinion valve assembly and install to the gear housing assembly.

    Recommended fluid 

    Power steering fluid (PSF-3)

    Recommended grease 

    Multipurpose grease SAE J310a, NLGI #2 EP

    Fig 8: Identifying Pinion Valve Lubrication Locations
    G00721923Courtesy of HYUNDAI MOTOR CO.
  13. Install the ball bearing using the special tool (09222-21100).
  14. Install the pinion and valve assembly to the valve housing.
    Fig 9: Installing Pinion Valve & Bearing
    G00721924Courtesy of HYUNDAI MOTOR CO.
  15. Install the oil seal using the special tool (09432-21601).
  16. Install the snap ring with snap ring pliers.
    Fig 10: Installing Pinion Valve Oil Seal
    G00721925Courtesy of HYUNDAI MOTOR CO.
  17. With the pinion turned all the way clockwise, tighten the self-locking nut.
    CAUTION: Always replace the self-locking nut with a new one.
    Fig 11: Tightening Pinion Self-Locking Nut
    G00721926Courtesy of HYUNDAI MOTOR CO.
  18. Apply semi-drying sealant to the threaded section of the end plug and tighten to the specified torque.

    Tightening torque 

    50~70 Nm (500~700 kg.cm, 36~51 lb.ft)

  19. Stake the end plug at two points on its circumference with a punch.
    Fig 12: Installing End Plug
    G00721927Courtesy of HYUNDAI MOTOR CO.
  20. Install the tab washer and then the tie rod and hammer the tab washer end at two points to the tie rod.
    CAUTION:
    1. Align the tab washer pawls with the rack grooves.
    2. Use a new tab washer.
    Fig 13: Securing Tab Washer
    G00721928Courtesy of HYUNDAI MOTOR CO.
  21. Install the bushing, rack support, yoke support spring and rack plug in the order shown. Apply semi-drying sealant to the threaded section of the yoke plug support cover before installation.
    Fig 14: Installing Rack Bushing, Rack Yoke Support, Spring & Plug
    G00721929Courtesy of HYUNDAI MOTOR CO.
  22. With the rack placed at the center position, attach the yoke plug to the gear housing. Tighten the yoke plug within the range of 20-25 Nm (200-250 kg.cm. 14.5-18 lb.ft), using the special tool. Loosen the yoke plug for approximately 20° and tighten the locking nut to the standard value.

    Standard value 

    Total pinion torque:

    0.6~1.3 Nm (6~13 kg.cm, 0.4~0.9 lb.ft)

  23. After adjusting, install the yoke plug with lock nut.
    NOTE: When it cannot be adjusted within the specified return angle, check rack support plug components or replace.
  24. Tighten the feed tube to the specified torque and install the mounting rubber with adhesive.
    Fig 15: Tightening Yoke Plug
    G00721930Courtesy of HYUNDAI MOTOR CO.
  25. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.

    Recommended grease 

    Multipurpose grease SAE J310a, NLGI #2 EP

  26. Install the new attaching band to the bellows.
    CAUTION: Whenever the bellows are installed, a new band must be used.
    Fig 16: Installing Steering Gear Bellows
    G00721931Courtesy of HYUNDAI MOTOR CO.
  27. Install the bellows in, taking care not to twist it.
  28. Fill the dust cover inner side and lip with the specified multipurpose grease, and place the dust cover in position with the clip ring attached in the groove of the tie rod end.

    Recommended grease 

    Multipurpose grease SAE J310a, NLGI #2 EP

    Fig 17: Installing Tie Rod End Ball Joint Dust Cover
    G00721932Courtesy of HYUNDAI MOTOR CO.
  29. Install the tie rods so that the length of the left and right tie rods equals the standard value.
    Fig 18: Installing Tie Rod End Ball Joint
    G00721933Courtesy of HYUNDAI MOTOR CO.
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