Hyundai Coupes/Sedans 1986-1993 Repair Guide

Manual Steering Rack

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Complete gear replacement with a new or reconditioned unit may be more cost and/or time efficient than repairing the original unit and may reduce the risk of damage or injury due to a part failure. Assessment of the situation may prove to be beneficial.

ADJUSTMENT



Excel and Scoupe
  1. Mount the rack and pinion assembly in a soft jawed vise, clamping on the rack mounting area, only.
  2.  
  3. Using a spline adapter on an inch-pound torque wrench, turn the pinion shaft at the rate of 1 full turn every 4-6 seconds, turning the steering from lock-to-lock. Measure the total preload lock-to-lock. Preload should be 3.6-9.6 inch lbs.
  4.  
  5. Place a pull scale on each tie rod end, in turn and pull straight away. The rack starting force should be 11-66 lbs.
  6.  
  7. If the specifications in either Steps 2 or 3 are not met, the rubber cushion and yoke spring behind the pinion shaft nut will have to be replaced.
  8.  

REMOVAL & INSTALLATION



Excel and Scoupe
  1. Loosen the lug nuts.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the steering shaft-to-pinion coupling bolt.
  8.  
  9. Disconnect the tie rod ends with a separator.
  10.  
  11. Removing the clamps securing the rack to the crossmember and remove the unit from the vehicle. The tie rod ends can now be removed. Prior to removal, count the exact number of exposed threads on the tie rod ends, then loosen the locknut and unscrew the tie rod end. When installing new tie rod ends, oil the threads and screw them into place so the previously noted number of threads is visible with the locknut tight. As a further reference, the distance between the end of the tie rod boot and the centerline of the tie rod ball stud should be 9.6 in. (243.5mm). Torque the locknut to 38 ft. lbs. (52 Nm).
  12.  

To install:
  1. Install the rubber mount for the gear box with the slit on the downside.
  2.  
  3. Observe the following torques:

    Rack-to-crossmember bolts-22-29 ft. lbs. (25-39 Nm) for 1986-1989 Excel models, 43-58 ft. lbs. (58-78 Nm) for 1990-93 Excel and Scoupe
     
    Coupling bolt-11-14 ft. lbs. (15-19 Nm)
     
    Tie rod end slotted nuts-11-25 ft. lbs. (15-34 Nm)
     

  4.  

 
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