Hyundai Sonata: Electric Power Steering / Steering Gear box Repair procedures

Removal
1.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the wheel cap (A).

   
Be careful not to damage to the wheel cap(A) when removing the it.
3.
Remove the front wheel and tire (A) from front hub.

Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

   
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4.
Remove driveshaft nut (A) from the front hub under applying the brake.

Tightening torque :
274.6 ~ 294.2 N.m (28.0 ~ 30.0 kgf.m, 202.5 ~ 217.1 lb-ft)

   
The front hub coking nut should be replaced with new ones.
After installation coking nut (A), stake the coking nut using a chisel and hammer as shown in the illustration below.

5.
Remove the tie rod end ball joint (C) from the knuckle.
(1)
Remove the split pin (A).
(2)
Remove the castle nut (B).

Tightening torque :
34.3 ~ 44.0 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

6.
Loosen the lower arm mounting and then remove the lower arm (A).
(1)
Remove the split pin (B).
(2)
Loosen the mounting nut and bolt.

7.
Loosen the stabilizer link (A) and remove it from the shock absorber.

Tightening torque :
98.0 ~ 117.6 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.7 lb-ft)

8.
Loosen the universal joint bolt (A) and then disconnect the universal joint assembly.

Tightening torque :
32.4 ~ 37.3 N.m (3.3 ~ 3.8 kgf.m, 23.9 ~ 27.5 lb-ft)

9.
Remove the engine room under cover (A).

Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

10.
Disconnect the connector (A). [R-MDPS Type]

11.
Remove the roll rod bracket (A).

Tightening torque :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

12.
Disconnect the muffler rubber hanger (A).

13.
Loosen the bolts & nuts and then remove the sub frame (A).

Tightening torque
Sub frame mounting bolt & nut :
156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)
Sub frame stay mounting bolt :
44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)

14.
Remove the steering gear box. [R-MDPS Type]
(1)
Loosen the bolts and then remove the portector (A).

Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(2)
Loosen the bolts and then remove the steering gear box (A).

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 43.4 ~ 57.9 lb-ft)

15.
Loosen the bolts and then remove the steering gear box (A). [C-MDPS Type]

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 43.4 ~ 57.9 lb-ft)

16.
Installation is reverse of the removal.
Replacement
   
Do not disassembly the steering gear box.
If disassembly the steering gear box, the quality(Noise / cleanliness / functions) is not guaranteed.

Tie rod end
1.
Remove the tie rod end after loosening the nut.

Tightening torque :
49.0 ~ 53.9 N.m 5.0 ~ 5.5 kgf.m, 36.2 ~ 39.8 lb-ft)

   
Before removing the tie rod end, note by measuring the length of the thread or marked with paint.
2.
Replace with new parts.
3.
Check the alignment.
(Refer to Tires/Wheels - "Alignment")
Dust cap
1.
Remove the dust cap cover.

2.
Pull the upwards and remove the dust cap.

3.
Installation is the reverse of removal.
Steering Gear box Components and Components Location
Components [C-MDPS] 1. Steering gear box2. Stabilizer bar3. Sub frame4. Bellows5. Tie rod end6. Heat protect [R-MDPS] 1. Steering gaer box2. Stabilizer bar3. Sub frame4. Bellows5. Tie rod ...

Restraint
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