This procedure covers the removal and replacement of the pitman arm on a 2015 Kia Forte with 1.8L I4 engine, though this vehicle uses rack-and-pinion steering and does not have a pitman arm.

Warnings

Tools required

Parts

• Pitman arm (if applicable - verify steering system type) × 1 — Use OEM specification
• Pitman arm nut (if reusable nut shows wear) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Fluids

• Kia PSF-4 — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and lock ignition
4. Raise front of vehicle with floor jack and support on jack stands at manufacturer-recommended lift points
5. Remove both front wheels
6. Verify steering system type - confirm presence of pitman arm and steering box (not typical for this vehicle)
7. Spray pitman arm nut and taper connections with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Mark steering alignment position
   Using a paint marker or scribe, mark the current position of the pitman arm relative to the steering box sector shaft. This ensures proper alignment during reinstallation and maintains steering wheel centering.
2. 2

   Remove pitman arm nut
   Using a breaker bar and appropriate socket, loosen and remove the pitman arm retaining nut from the steering box sector shaft. Note the position of any washers. The nut is torqued to 185 Nm and will require significant force to break loose.
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
3. 3

   Separate pitman arm from sector shaft
   Install a pitman arm puller onto the arm, ensuring the puller jaws are seated properly behind the arm. Tighten the puller screw gradually while supporting the pitman arm. Do not use a pickle fork as this will damage the seal on the steering box. The taper fit will release with a loud pop. Remove the puller and lift the pitman arm slightly off the shaft.
   ⚠Never strike the pitman arm or steering box with a hammer - this can damage internal components and seals
4. 4

   Disconnect center link or drag link
   If the pitman arm is still connected to the center link or drag link, remove the cotter pin and castle nut from the ball joint connection. Use a tie rod separator tool to press the ball stud out of the pitman arm socket. Support the center link to prevent it from dropping.
   Torque spec

   Tie Rod Nut52 Nm (38 lb-ft)
5. 5

   Remove pitman arm
   With all connections separated, slide the pitman arm off the steering box sector shaft. Inspect the sector shaft splines for wear or damage. Clean any rust or debris from the shaft with a wire brush.
6. 6

   Inspect and prepare replacement pitman arm
   Compare the old and new pitman arms to ensure they are identical in length, spline count, and ball joint configuration. Clean the internal splines of the new pitman arm. Apply a thin coat of anti-seize to the sector shaft splines (avoid getting any on the taper surfaces).
7. 7

   Install new pitman arm
   Align the splines of the new pitman arm with the sector shaft, matching the alignment marks made during removal. Slide the pitman arm onto the shaft, ensuring it seats fully against the shoulder. The arm should slide on with moderate hand pressure once properly aligned.
   ⚠Do not force the pitman arm onto the shaft - misaligned splines can damage both components
8. 8

   Install and torque pitman arm nut
   Install the pitman arm nut onto the sector shaft with any washers in their original positions. Using a torque wrench, tighten the nut to 185 Nm (136 lb-ft). Verify the pitman arm is fully seated and the alignment marks still match.
   Torque spec

   Pitman Arm Nut185 Nm (136 lb-ft)
9. 9

   Reconnect center link or drag link
   Clean the ball stud and taper seat in the pitman arm. Position the center link or drag link ball stud into the pitman arm socket. Install the castle nut and tighten to 52 Nm (38 lb-ft). Install a new cotter pin through the castle nut and ball stud, bending the ends to secure.
   Torque spec

   Tie Rod Nut52 Nm (38 lb-ft)
10. 10

    Check power steering fluid level
    With the vehicle still raised, check the power steering fluid reservoir. Top off with Kia PSF-4 fluid to the MAX mark if fluid was lost during the procedure. Start the engine and turn the steering wheel lock-to-lock several times to purge air from the system. Recheck fluid level and top off as needed.
11. 11

    Reinstall wheels
    Mount the front wheels onto the hubs, threading lug nuts by hand. Lower the vehicle until the wheels just contact the ground. Torque the lug nuts to 129 Nm (95 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Ensure cotter pins are properly installed and bent
3. Check for any power steering fluid leaks around connections
4. Verify steering wheel is centered when wheels point straight ahead

Verification

• Start the engine and verify no unusual noises from the steering system
• Turn the steering wheel lock-to-lock while stationary - operation should be smooth with no binding
• Check power steering fluid level after test - top off if necessary
• Test drive the vehicle at low speed in a safe area to verify steering response and centering
• Schedule a professional wheel alignment - steering geometry has been altered and alignment is required
• Inspect under vehicle for any fluid leaks after test drive
• Re-verify the 2015 Kia Forte steering system type - if rack-and-pinion is confirmed, this procedure does not apply

More procedures for this vehicle