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HOMESERVICE MANUALSHYUNDAI1994ELANTRA BASE, 1.8 MREPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGPOWER STEERINGSTEERING SYSTEM - POWER RACK & PINIONOVERHAULSTEERING GEARREASSEMBLY
1994 Hyundai Elantra Base, 1.8 M

Steering Gear: Reassembly

1994 Hyundai Elantra Base, 1.8 MSECTION Reassembly
  1. Apply Dexron-II ATF to all "O" rings. Use multipurpose grease to lubricate rack teeth, bearings and teeth on pinion valve assembly. Reassemble in reverse order of disassembly.
  2. Using Driver Handle (09555-21000 ) and appropriate guide and installer, seat back-up washer and oil seal in gear housing. See POWER STEERING GEAR ASSEMBLY EQUIPMENT  table. See Fig 1 . Using correct bearing installer, seat NEW bearings (needle, taper or ball) in gear housing.
    Fig 1: Installing Seal To Gear Housing
    G93J00975Courtesy of HYUNDAI MOTOR CO.
  3. Using correct seal installer, seat rack bushing seal. Install NEW "O" ring onto rack bushing. Install lubricated rack into gear housing. DO NOT cover rack vent hole with grease.
  4. Install rack bushing and rack stopper. Push in rack stopper until snap ring groove of rack stopper is aligned with slotted hole in rack housing. Install circlip while turning rack stopper. When installed, end of circlip should not be visible through slotted hole in rack housing. See Fig 2 .
    POWER STEERING GEAR ASSEMBLY EQUIPMENT

    Application Part No.
    Gear Housing Tapered Bearing Installer 09432-21600
    Gear Housing Ball Bearing Installer 09222-21100
    Rack Bushing Oil Seal Installer 09434-14200
    Rack Oil Seal Installer Gauge 09573-21000
    Rack Oil Seal Installer 09573-21100
    Rack Oil Seal Installer Guide 09573-21200
    Rack Support Cover Socket 09565-21100
    Valve Body Oil Seal Installer 09434-14200
    Fig 2: Positioning Circlip
    G90I07779Courtesy of HYUNDAI MOTOR CO.
  5. Use Installer (09432-21600 ) to seat oil seal and ball bearing into valve body. Install sealing rings onto pinion valve assembly. Apply multipurpose grease to pinion valve assembly gears and Dexron-II fluid to valving areas. See Fig 3 . Install pinion valve into gear housing.
    Fig 3: Lubricating Pinion Valve Assembly
    G90I02734Courtesy of HYUNDAI MOTOR CO.
  6. Use Seal Installer (09434-14200 ) to seat seal and bearing into valve body housing. See Fig 4 . Seal Installer (09432-21601 ) to seat bearing and seal into valve housing.
  7. Install NEW gear housing-to-gear box oil seal and install gear box to rack housing. Install tab washer and then tie rod. Align tab washer tabs with grooves in rack. Stake tab washer into place.
  8. With pinion shaft turned fully clockwise, tighten a NEW self-locking nut to specification. Tighten end plug to specification. Using a punch, stake plug in 2 locations on its circumference.
    Fig 4: Exploded View Of Power Steering Gear
    G93A00976Courtesy of HYUNDAI MOTOR CO.
  9. Install rack support bushing, rack support and rack support spring into rack. Center rack in housing. Install rack support cover. Move rack to center position. Tighten rack support cover to 11 ft. lbs. (15 N.m).
  10. Loosen cover approximately 10 degrees. Install lock nut and tighten to specification. See TORQUE SPECIFICATIONS  table.
  11. Install hydraulic feed tubes. Lubricate boot attaching groove in tie rod with multipurpose grease. Slide NEW rubber boot attaching band onto tie rod.
  12. Carefully install boot in position. DO NOT twist boot. Install attaching band onto boot. Fill tie rod end with multipurpose grease, and install NEW dust cover with clip ring.
  13. Install tie rod ends. Adjust length of each tie rod. Measure from outer edge of clamped boot to outer edge of tie rod lock nut. See TIE ROD INSTALLED LENGTH  table. Check and adjust pinion preload as necessary. See PINION PRELOAD  under ADJUSTMENTS.
TIE ROD INSTALLED LENGTH

Application In. (mm)
Elantra 7.1 (181)
RENDER: 1.0x

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