Kia Carens. Manual - part 112

8. Connect rod seal to grease coated surface of housing insert.

9. Apply ATF to inside and outside of housing insert and rod seal.

10. Set housing insert and rod seal on suitable tool.

11. Insert suitable tool from tube side of gear housing.

12. Install and tighten suitable tool nut against tube.

13. Turn suitable tool shaft in as far as it will go to push in rod seal and housing insert.

14. Remove suitable tool.

15. Apply grease (lithium base, NLGI No.2) to friction surface and teeth of rack.

16. Slide suitable tool over rack and slide it in from tube side of gear housing.

17. Remove suitable tool.

18. Apply sealant to thread area of rack bushing .

19. Install rack bushing assembly in rack housing.

20. Tighten tack busing as rod seal goes into tube.

Tightening torque : 65~72 lb-ft (88~98 N·m, 9~10 kg-m)

Rod seal is pushed to correct position in rack housing by tightening of rack bushing.

21. Connect suitable tool to cylinder housing.

22. Connect a vacuum pump to suitable tool.

23. Apply 15.7 inHg(400 mmHg) vacuum.

24. Verify that vacuum is held for at least 30 seconds. If not, check seal and assembly.

25. Secure gear housing in a vise so that lower bearing bore faces upward.

26. Apply ATF (Automatic Transmission Fluid) to lower bearing, then install in housing.

27. Press bearing into gear housing with pinion cover. Tighten pinion plug until tightening force suddengly

increases.

28. Apply grease (lithium base, NLGI No.2) to teeth of pinion shaft.

29. Apply ATF to seal ring and friction surface of control valve.

30. Install pinion shaft in housing.

1) Be careful not to damage oil seal with pinion teeth.
2) Be careful not to damage edge of seal ring and control valve.

31. Apply ATF to input shaft bearing, and then install it.

32. Apply ATF to oil seal, and fill inside lip with grease (lithium base, NLGI No.2).

33. Slide suitable tool over serrations of pinion shaft assembly.

34. Slide suitable tool over serrations of pinion shaft assembly.

35. Slide oil seal over suitable tool and position it in housing.

36. Tap oil seal in with suitable tool until snap ring installation groove in housing is just visible.

Apply uniform force to oil seal when installing.

37. Temporarily install tie roe on tube side of rack housing.

38. Install locknut on pinion shaft assembly and turn it until tie rod contacts tube.

39. Tighten locknut.

Tightening torque : 29~36 lb-ft(39~49 N·m, 4.0~5.0 kg-m)

40. Apply thread sealant to housing cover treads.

41. Install housing cover.

Tightening torque : 33~40 lb-ft(44~54 N·m, 4.5~5.5 kg-m)

42. Stake between rack housing and pinion plug cover at two points with a center punch.

43. Secure gear housing in a vise so that support yoke position faces upward.

44. Apply grease (Lithium base, NLGI No.2) to rack sliding surface of support yoke ; then install in housing.

45. Install support yoke.