Kia Optima Hybrid: Electric Power Steering / Steering Gear box Repair procedures

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) from 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, 25.7 ~ 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.
Remove the front lower arm from the front knuckle using the SST (0K545-A9100).
(1)
After removing bolts from the front knuckle, install and tighten the sub body bolt (A) .

(2)
Input the sub body (A) between the front knuckle and the sub body bolt.
(3)
Tighten bolt (B) of the sub body bolt to broaden the gap of the front knuckle.

(4)
Install the safe wire (A).

   
Install a safe wire on the front strut to prevent dropping the SST and hurting technicians.
(5)
Install the main body, between the front strut and the lower arm.

(6)
To avoid the main body coming off, install a fixing clamp (A) beside the main body.

(7)
After installing a fixing clamp, rotate the handle (B) clock wise till the clamp is fixed on a lower arm.

(8)
Tighten a main body bolt (A) of the slowly and remove the lower arm from the front knuckle.

6.
Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.

Tightening torque :
29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.7lb-ft)

   
Keep in the neutral-range to prevent damage of the clock spring inner cable when you handle the steering wheel.
Do not use the bolt again.
7.
Remove the under cover (A).

8.
Loosen the bolt (A) & nut (B) and then remove the roll rod stopper.

Tightening torque :
107.9 ~ 127.5N.m (11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)

9.
Disconnect the muffler rubber hanger (A).

10.
Loosen the bolts & nuts and then remove the sub frame (A).

Tightening torque
Sub frame mounting bolts & nuts:
156.9 ~ 176.5N.m (16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
Sub frame stay bolts & nuts:
44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

11.
Remove the stabilizer bar.
12.
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)

13.
Installation is the reverse of the removal.
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
Check the rack gear for damage.
Check the rack bar for bend and deformation.

2.
Pinion assembly
Check the pinion gear for damage
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

Components 1. Tie rod end2. Lock nut3. Bellows 4. Bellows band5. Tie rod6. Rack bar 7. Dust packing 8. Dust cap9. Oil seal10. Pinion plug11. Pinion assembly12. Yoke plug13. Yoke spring14. Support yoke ...

Restraint

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Other information:

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