A $2 rubber part behind a knock in the steering wheel

The owner brought in their Elantra, now at 356,000 km, because of a knocking noise they could feel and hear from the steering wheel over uneven roads and bumps.

We took it for a road test and heard the same knock.

Steering coupler: The coupler, a small rubber gear between the electric power steering motor and the steering shaft, had completely deteriorated and was crumbling apart (photo 4). The coupler passes the motor's assist into the steering shaft. Once it wears, there is play between the two, which is what makes the knock over bumps. Left too long, that looseness can damage more expensive parts like the steering shaft or the motor itself. Since it is part of the steering, it is worth fixing rather than living with.

• Road tested the car and confirmed the knocking noise
• Inspected the steering and suspension components; no other issues found
• Found a Hyundai technical service bulletin matching the noise
• Removed the steering column, electric steering motor and steering shaft (photos 2 and 3)
• Replaced the steering coupler with an original Hyundai part (photo 1)
• Reassembled the steering and performed a zero point calibration
• Checked the wheel alignment

After everything went back together, the knock was gone. The part itself costs about $2, but reaching it takes around three hours of labour, because the steering column, motor and shaft all have to come out.

Our technician has done this repair before. It is very common on the Elantra and Sonata. If your steering wheel knocks over bumps and the suspension checks out fine, this coupler is a likely suspect, and catching it early helps protect the steering shaft and motor.

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