Hyundai Kona: Motor Driven Power Steering / Steering Gear Box Repair procedures

Removal
1.
Loosen the wheel nuts slightly.
2.
Raise the vehicle, and make sure it is securely supported.
3.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

4.
Disconnect the stabilizer link with the front strut assembly after loosening the nut (A).
Tightening torque :
98.1 - 117.7 N.m (10.0 - 12.0 kgf.m, 72.3 - 86.8 lb-ft)

  
When loosening the nut (A), fix the outer hexagon of stabilizer bar link.
Be careful not to damage the stabilizer link boots.
5.
Remove the tie rod end ball joint.
(1)
Rmove the split pin (C).
(2)
Loosen the nut (B).
(3)
Using SST(09568-1S100), separate the ball joint (A) from the knuckle.
Tightening torque :
24.5 - 34.3 N.m (2.5 - 3.5 kgf.m, 18.1 - 25.3 lb-ft)

6.
Loosen the lower arm nut (A) and then remove the lower arm ball joint by using SST(09568-1S100).
Tightening torque :
58.8 - 70.6 N.m (6.0 - 7.2 kgf.m, 43.4 - 52.1 lb-ft)

  
Do not reuse the lower arm lock nut (A).
7.
Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.
Tightening torque :
32.4 - 37.3 N.m (3.3 - 3.8 kgf.m, 23.9 - 27.5 lb-ft)

  
Do not reuse the bolt.
Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner cable.
When assembling, insert the shark pin into the universal joint york slot as the below illustration.

8.
Remove the heated protector (A).

9.
Remove the muffler rubber hanger (A).

10.
Remove the roll rod bracket (C) by loosening the bolt (A), (B).
Tightening torque
(A) : 107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
(B) : 49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)

11.
Remove the subframe by loosening the mounting bolts and nuts.
  
Set a transmission jack for safety.
Tightening torque
Sub frame mounting bolts and nut :
176.5 - 196.1 N.m (18.0 - 20.0 kgf.m, 130.2 - 144.7 b-ft)
Sub frame stay mounting bolt :
44.1 - 53.9 N.m (4.5 - 5.5 kgf.m, 32.5 - 39.8 lb-ft)

12.
Loosen the mounting bolts and then remove the stabilizer bar (A).
Tightening torque :
44.1 - 53.9 N.m (4.5 - 5.5 kgf.m, 32.5 - 39.8 lb-ft)

13.
Remove the heated protector (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)

14.
Remove the steering gearbox (A) from the front sub frame by loosening the mounting bolts.
Tightening torque :
88.2 - 107.8 N.m (9.0 - 11.0 kgf.m, 65.0 - 79.5 lb-ft)

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")
Installation
1.
Install in the reverse order of removal.
2.
Check the alignment.
(Refer to Tires / Wheels - "Alignment")
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Restraint
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