Hyundai Elantra HD: Steering Gear box. Repair procedures - Electric Power Steering - Steering System - Hyundai Elantra HD 2006–2010 Service ManualHyundai Elantra HD: Steering Gear box. Repair procedures

Removal

1.
Remove the front wheel & tire.
2.
Loosen the bolt (A) and then disconnect the universal joint assembly (B) with the pinion of the steering gear box.

Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering wheel.
3.
Disconnect the stabilizer link (A) from the front strut assembly by loosening the nut.
4.
Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle by using a SST (09568-34000).
5.
Disconnect the front lower arm with the knuckle by loosening the mounting bolts (A).
6.
Remove the muffler rubber hanger (A).
7.
Loosen the wiring harness protector bolts (A).
8.
Remove the front and rear roll stopper bolt and nut (A, B).
9.
Remove the sub frame (E) and sub frame stay by loosening the mounting bolts (A, C) and nuts (B, D).
10.
Remove the rear roll stopper (A) from the sub frame by loosening mounting bolts.
11.
Remove the steering gear box (A) from the sub frame by loosening the mounting bolts.

Disassembly

1.
Remove the dust packing & cap (A) from the pinion housing.
2.
Loosen the lock nut and then remove the tie rod end (B) and lock nut (A) from the tie rod.
3.
Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie rod.
4.
Remove the tie rod (B) from the rack bar (A) by unscrewing the tie rod inner ball joint.
5.
Remove the plug (A) from the pinion housing.
6.
Remove the oil seal (B) from the plug (A).
7.
Remove the yoke plug (A) and spring (B) and then pull out the support yoke (C).
8.
Remove the O-rings (B) from the support yoke assembly (A).
9.
Pull the pinion assembly (A) out of the pinion housing.
10.
Pull the rack bar (A) out of the rack housing.

Inspection

1.
Rack bar
A.
Check the rack gear for damage.
B.
Check the rack bar for bend and deformation.
2.
Pinion assembly
A.
Check the pinion gear for damage.
B.
Check the surface contacting the oil seal for damage.
C.
Check the oil seal for damage.
3.
Check the inside of rack housing for damage.
4.
Check the bellows for being torn.

Reassembly

1.
Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack hosing.
2.
Insert the pinion assembly (A) into the pinion housing.
3.
Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.
4.
Assemble new O-rings (B) to support yoke (A).
5.
Insert the support yoke assembly (C) into the housing.
6.
Apply the sealant to the thread of the yoke plug and then assemble the yoke plug (A) and the yoke spring (B) together.
7.
Apply the grease to the edge of the new oil seal (B) and then assemble it to the pinion plug (A).
8.
Apply the sealant to the thread of the plug and then assemble the pinion plug (A) to the housing.
Tightening torque :
60 ~ 80N.m (6.0 ~ 8.0kgf.m, 43 ~ 58lb-ft)

9.
Apply loctite (Three bond-1374) to the thread of the tie rod inner ball joint and then assemble the tie rod (A) to the rack bar (B).
Tightening torque :
110 ~ 130N.m (11.0 ~ 13.0kgf.m, 65 ~ 94lb-ft)

10.
Assemble new bellows band (A) to the bellows.
11.
Apply the grease (Kyoto Yushi-One Luber2128 to the portion (D) of the tie-rod.
12.
Apply the sealant (Three bond-1141E) to the bellows mating surface of therack housing.
13.
Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).
14.
Assemble the lock nut (A) and tie rod end (B) to tie rod.

Installation

1.
Install the steering gear box (A) to the sub frame by tightening the mounting bolts.
Tightening torque :
60 ~ 80N.m (6.0 ~ 8.0kgf.m, 43 ~ 58lb-ft)

2.
Install the rear roll stopper (A) to the sub frame by tightening the mounting bolts.
Tightening torque :
50 ~ 65N.m (5.0 ~ 6.5kgf.m, 36 ~ 47lb-ft)

3.
Install the sub frame (E) and sub frame stay by tightening the mounting bolts (A, C) and nuts (B, D).
Tightening torque
Sub frame mounting bolts (C) and nuts (D):
160 ~ 180N.m (16.0 ~ 18.0kgf.m, 116 ~ 130lb-ft)
Sub frame stay mounting bolt (A) and nut (B):
45 ~ 55N.m (4.5 ~ 5.5kgf.m, 33 ~ 40lb-ft)

4.
Tighten the front and rear roll stopper bolt and nut (A, B).
Tightening torque :
50 ~ 65N.m (5.0 ~ 6.5kgf.m, 36 ~ 47lb-ft)

5.
Install the wiring harness protector to the sub-frame by tightening the bolts (A).
6.
Install the muffler rubber hanger (A).
7.
Connect the lower arm with the knuckle by tightening the bolts (A).
Tightening torque :
100 ~ 120N.m (10.0 ~ 12.0kgf.m, 72 ~ 87lb-ft)

8.
Connect the tie rod end with the knuckle and then install the castle nut and split pin.
Tightening torque :
24 ~ 34N.m (2.4 ~3.4kgf.m, 17 ~ 25lb-ft)
9.
Connect the stabilizer link (A) with the front strut assembly and than tighten the nut.
Tightening torque :
100 ~ 120N.m (10.0 ~ 12.0kgf.m, 72 ~ 87lb-ft)

10.
Connect the universal joint assembly (B) with the pinion of the steering gear box and then tighten the bolt (A).
Tightening torque :
30 ~ 35N.m (3.0 ~ 3.5kgf.m, 22 ~ 25lb-ft)

11.
Install the front wheel & tire.
Tightening torque :
90 ~ 110N.m (9.0 ~ 11.0kgf.m, 65 ~ 80lb-ft)
12.
Check the alignment. (Refer to SSgroup 'Tires/Wheels - alingment')
13.
Perform the ASP (Absoulte Steering Position) calibration procedure. (Refer to ASP calibration)
If the ASP calibration procedure is not performed, EPS warning lamp will be turned on or flicker and behicle may pull to the left or the right.

Steering Gear box. Components and Components Location
Components 1. Tie rod end 2. Lock nut 3. Bellows clip 4. Bellows 5. Tie rod 6. Dust packing & Cap 7. Pinion plug & Oil seal 8. Pinion assembly ...

Restraint
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