Hyundai Coupes/Sedans 1986-1993 Repair Guide

Power 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 in a soft jawed vise, clamping the vise on the rack mounting areas, only.
  2.  
  3. Using a spline adapter on an inch-pound torque wrench, rotate the pinion shaft several times, lock-to-lock and note the total pinion preload. Preload should be 5-11 inch lbs.
  4.  
  5. If the preload is note within specifications, adjust the position of the rack support cover and recheck the preload. If it does not work, the rack support cover components are defective.
  6.  

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. Drain the fluid.
  12.  
  13. Disconnect the hoses from the steering gear.
  14.  
  15. Remove the band from the steering joint cover.
  16.  
  17. Unbolt and remove the stabilizer bar.
  18.  
  19. Remove the rear roll stopper-to-center member bolt and move the rear roll stopper forward, as required.
  20.  
  21. Remove the rack unit mounting clamp bolts and take the unit out the left side of 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.
  22.  

To install:
  1. 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 point at which the locknut touches the tie rod ball socket body should be 6.1-6.2 in. (155.5-157.5mm); 6.9-7.0 in. (174.3-176.3mm) for Scoupe. Torque the locknut to 38 ft. lbs. (52 Nm).
  2.  
  3. When installing the power steering rack, make sure the rubber isolators have their nubs aligned with the holes in the clamps.
  4.  
  5. Apply rubber cement to the slits in the gear mounting grommet.
  6.  
  7. Tighten the clamp bolt to 43-58 ft. lbs. (58-78 Nm), the tie rod end slotted nuts to 11-25 ft. lbs. (14-34 Nm) and the coupling bolt to 11-14 ft. lbs. (14-19 Nm).
  8.  
  9. Fill the system with Dexron®II ATF.
  10.  

Elantra and Sonata
  1. Raise the vehicle and support it safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Drain the fluid from the power steering system.
  6.  
  7. Remove the steering shaft-to-pinion coupling bolt.
  8.  
  9. Remove the retainer nut and disconnect both tie rod ends using an appropriate puller.
  10.  
  11. Disconnect the left lower arm from the steering knuckle. This will increase clearance as the gear assembly will be removed from the left side of the vehicle.
  12.  
  13. Disconnect the fluid hoses from the gear box.
  14.  
  15. Remove the center member and temporarily retighten the front muffler.
  16.  
  17. Unbolt and remove the stabilizer bar.
  18.  
  19. Remove the rack unit mounting clamp bolts and move the rack towards the right and then take the unit out on the left side of 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.
  20.  

To install:
  1. 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 point at which the locknut touches the tie rod ball socket body should be 187.4mm. Torque the locknut to 38 ft. lbs. (52 Nm).
  2.  
  3. When installing the power steering rack, make sure the rubber isolators have their nubs aligned with the holes in the clamps.
  4.  
  5. Apply rubber cement to the slits in the gear mounting grommet. Tighten the clamp bolt to 43-58 ft. lbs. (58-78 Nm), the tie rod nuts to 11-25 ft. lbs. (14-34 Nm) and the coupling bolt to 22-25 ft. lbs. (29-34 Nm).
  6.  
  7. Fill the system with Dexron®II ATF.
  8.  

 
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