Hyundai Sonata: Steering Gear box. Repair procedures - Revised - Electric Power Steering - Steering SystemHyundai Sonata: Steering Gear box. Repair procedures - Revised

Hyundai Sonata YF 2011-2014 Service Manual / Steering System / Electric Power Steering / Steering Gear box. Repair procedures - Revised

Replacement

1.
Remove the front wheel & tire.
Tightening torque :
88.3 ~ 107.9N.m(9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Be careful not to damage to the hub bolts when removing the front wheel & tire.
2.
Disconnect the stabilizer link (B) with the front strut assembly (A) after loosening the nut.
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

3.
Remove the split pin and castle nut and then disconnect the tie-rod end (A) from the front knuckle.
Tightening torque :
34.3 ~ 44.1N.m(3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)

4.
Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

5.
Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.
Tightening torque :
32.4 ~ 37.3N.m(3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)

Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner cable when you handle the steering wheel.
6.
Loosen the bolt (A) & nut (B) and then remove the front roll stopper.
Tightening torque :
107.9 ~ 127.5N.m(11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)

7.
Loosen the rear roll stopper mounting bolts (A).
Tightening torque :
49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

8.
Disconnect the muffler rubber hanger (A).
9.
Loosen the bolts & nuts and then remove the sub frame.
Tightening torque :
Sub frame mounting bolts & nuts:
156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
Sub frame bracket bolts:
44.1 ~ 58.8N.m(4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

10.
Loosen the bolt and then remove the protactor.
11.
Loosen the bolt and then remove the steering gear box (A).
Tightening torque :
88.3 ~ 107.9N.m(9.0 ~ 11.0Kgf.m, 65.1 ~ 79.6lb-ft)

12.
Installation is the reverse of the removal.
13.
Check the alignment. (Refer to SS group 'Tires/Wheels - alingment')

Replacement

1.
Remove the front wheel & tire.
Tightening torque :
88.3 ~ 107.9N.m(9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Be careful not to damage to the hub bolts when removing the front wheel & tire.
2.
Disconnect the stabilizer link (B) with the front strut assembly (A) after loosening the nut.
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

3.
Remove the split pin and castle nut and then disconnect the tie-rod end (A) from the front knuckle.
Tightening torque :
34.3 ~ 44.1N.m(3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)

4.
Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

5.
Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.
Tightening torque :
32.4 ~ 37.3N.m(3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)

Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner cable when you handle the steering wheel.
6.
Remove the under cover (A).
7.
Loosen the bolt & nut and then remove the roll rod stopper (A).
8.
Disconnect the muffler rubber hanger (A).
9.
Loosen the bolts & nuts and then remove the sub frame.
Tightening torque :
Sub frame mounting bolts & nuts:
156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
Sub frame bracket bolts:
44.1 ~ 58.8N.m(4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

10.
Loosen the bolt and then remove the protactor.
11.
Loosen the bolt and then remove the steering gear box (A).
Tightening torque :
88.3 ~ 107.9N.m(9.0 ~ 11.0Kgf.m, 65.1 ~ 79.6lb-ft)

12.
Installation is the reverse of the removal.
13.
Check the alignment.
(Refer to SS group 'Tires/Wheels - alingment')

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-ring (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.
11.
Reassembly is the reverse of the disassembly.

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 oil seal for damage.
3.
Check the inside of rack housing for damage.
4.
Check the bellows for being torn.

    Steering Gear box. Components and Components Location
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