Steering Gear - Manual Hyundai Excel I

DESCRIPTION

Steering gear is a rack and pinion type. The steering gear is connected to the steering knuckles by tie rods. A flexible coupling connects the steering column to the steering gear assembly.

ADJUSTMENTS

Any adjustments are made during the reassembly procedure. See OVERHAUL in this article.

Removal

1. Disconnect battery ground cable. Raise and support vehicle. Remove both wheels. Remove "U" joint-to-pinion shaft clamp bolt. Remove tie rod end cotter pins and castle nuts.
2. Using a tie rod puller, separate tie rods from steering knuckles. Remove steering gear mounting bolts. Remove steering gear. Do not damage rubber boots.

Installation

To install, reverse removal procedure. Check and adjust toe-in.

Exploded View of Excel Rack & Pinion Steering Gear. Scheme 1

Disassembly

1. Mount steering unit in a soft-jawed vise. Remove tie rod assemblies. Remove adjusting plug lock nut. Remove adjusting plug, plunger spring, rubber cushion and rack support from housing.
2. Using a screwdriver, pry pinion shaft oil seal from housing. Remove pinion bearing retaining snap ring from housing. Remove pinion bearing with pinion shaft.
3. Remove bearing retaining snap ring from pinion shaft. Using an appropriate sized sleeve and a press, remove bearing from pinion shaft. Remove boot retaining clamps. Remove boots.
4. Using a chisel, unstake right side (opposite pinion shaft) rack end tab washer. Move rack all the way toward pinion shaft side of housing. Place exposed end of rack in vise. Use a copper plate to protect rack teeth.
5. Loosen tie rod ball joint. Remove tie rod from rack. Pulling toward the side of the pinion shaft, remove rack from housing.

Removing Rack From Housing. Scheme 2

Inspection

1. Check steering housing rubber mounts for deterioration or cracking. Inspect rack bushing for excessive play. Check for damage to rack teeth, pinion shaft teeth and pinion shaft splines.
2. Inspect bushing and seal mating surfaces for scratching and/or scoring. Check housing for cracks or dents. Inspect all rotating surfaces for wear. Replace components as necessary.

Reassembly

1. Clean all components in solvent. Always use new seals. Using an appropriate sized sleeve and a press, install pinion shaft bearing onto pinion shaft.
2. Install bearing retaining snap ring to pinion shaft. Grease the rack, pinion shaft, bushing, needle bearing and other sliding surfaces. NOTE: When lubricating components with grease, take care not to cover the air passage in the housing bushing.
3. Install rack into housing from the pinion shaft side of housing. Install pinion shaft into housing while meshing pinion shaft with rack teeth.
4. Check that rack is properly centered. Measure travel of rack at each end of housing. If not equal, remove pinion shaft. Recenter the rack. Reinstall pinion shaft. Select and install snap ring to minimize pinion shaft axial play. Refer to SNAP RING THICKNESS table. SNAP RING THICKNESS Color Code In. (mm) Blue .063 (1.59) White .066 (1.66) Yellow .069 (1.74)
5. Grease oil seal lip and oil seal-to-housing mating surface. Install oil seal into housing. Grease the rack support. Install rack support, rubber cushion, plunger spring and adjusting plug into housing. Center the rack.
6. Tighten adjusting plug to 60-132 INCH lbs. (7-15 N.m). Back off adjusting plug 30-60 degrees. Apply sealer to adjusting plug lock nut threads. Tighten adjusting plug lock nut to 36-51 ft. lbs. 50-70 N.m).
7. Install tie rod assemblies with new tab washers. Stake tie rod-to-rack end nuts. Install bellows and bellows clamps. Using a socket and torque wrench, measure pinion preload and rack starting force.
8. Pinion preload should be 4-10 INCH lbs. (.4-1.1 N.m). Rack starting force should be 6-11 ft. lbs. (8-15 N.m). If not within specification, replace plunger spring and rubber cushion. Recheck rack starting force and pinion preload.

1. Mount steering gear in a soft-jawed vise. Remove boot clamps. Remove boots. Using a chisel, unstake left tie rod. Move tie rod all the way to the right. Place rack in a soft-jawed vise. Loosen tie rod end nut.
2. Remove tie rod from rack. Repeat step 1) for right side tie rod, moving the rack to the left side this time to loosen the end nut.

1. Inspect ball joints for pitting or wear. Check for damaged or deformed tie rods. Check boots for cracking or cuts.
2. Check ball stud starting torque. Starting torque should be 8-26 INCH lbs. (1.0-2.9 N.m). If not within specifications, replace tie rod end.
3. Check for ball stud axial deflection. Deflection should be less than .06" (1.5 mm). If not within specification, replace tie rod end.

Install tie rod to rack. Tighten end nuts to 58-72 ft. lbs. 78-98 N.m). Install boots and boot clamps. Check and adjust toe-in.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• OVERHAUL