Mitsubishi 380. Manual — part 860

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-38

DISASSEMBLY AND ASSEMBLY

M1372011100223

Required Special Tools:

• MB991006: Preload Socket

• MB991204: Torque Wrench Socket

• MB991561: Boot Band Crimping Tool

13DB058A

7

5

2

1

6

84 ± 14 N·m

62 ± 10 ft-lb

52 ± 2 N·m

38 ± 2 ft-lb

3

4

8

9

10

11

59 ± 10 N·m

44 ± 7 ft-lb

12 ± 2 N·m*

107 ± 17 in-lb*

25 ± 4 N·m

18 ± 3 ft-lb

59 ± 10 N·m

44 ± 7 ft-lb

12

DISASSEMBLY STEPS

>>P<<

1.

STEERING GEAR NUT (TIE ROD
END JAM NUT)

>>P<<

2.

TIE ROD END ASSEMBLY

3.

STEERING GEAR INNER CLIP

>>O<<

4.

STEERING GEAR BAND (BELLOWS
BAND)

5.

STEERING GEAR BELLOWS

<<A>> >>N<<

6.

STEERING TIE ROD

<<A>> >>N<<

7.

STEERING GEAR WASHER (TAB
WASHER)

>>L<<

8.

STEERING GEAR INNER NUT (JAM
NUT)

<<B>> >>L<<

9.

STEERING GEAR RACK SUPPORT
COVER

>>K<<

10.

STEERING GEAR PLUG (END
PLUG)

11.

STEERING GEAR INNER NUT

12.

STEERING GEAR ASSEMBLY (less
tie rods)

>>M<<

•

TOTAL PINION TORQUE
ADJUSTMENT

DISASSEMBLY STEPS (Continued)

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-39

DISASSEMBLY SERVICE POINTS

.

<<A>> STEERING TIE ROD/STEERING GEAR
WASHER (TAB WASHER) REMOVAL

Unstake the tab washer which secures the tie rod and rack with
a chisel.

.

<<B>> STEERING GEAR RACK SUPPORT
COVER REMOVAL

Using special tool MB991204, remove the rack support cover
from the gear box.

ASSEMBLY SERVICE POINTS

.

>>K<< STEERING GEAR PLUG (END PLUG)
INSTALLATION

1. Apply 3M

TM

AAD Part number 8661, 8663, 8672, 8678,

8679 or equivalent to the threaded part of the end plug.

2. Secure the threaded portion of the end plug at two places by

using a punch.

.

AC001001AB

TAB WASHER

ACX01142AB

MB991204

ACX01162AB

END PLUG

END PLUG

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-40

>>L<< STEERING GEAR RACK SUPPORT
COVER/STEERING GEAR INNER NUT (JAM NUT)
INSTALLATION

1. Position the rack at its center.

2. Apply 3M

TM

AAD Part number 8661, 8663, 8672, 8678,

8679 or equivalent to the threaded part of the rack support
cover.

3. Use special tool MB991204 to tighten the rack support cover

to 12

± 2 N⋅m (107 ± 17 in-lb).

4. Turn the rack support cover 10 degree angle

counterclockwise.

5. Use special tool MB991204 to hold the rack support cover,

and then tighten the jam nut to 59

± 10 N⋅m (44 ± 7 ft-lb).

.

>>M<< TOTAL PINION TORQUE ADJUSTMENT

CAUTION

• Be sure there is no ratcheting or catching when operat-

ing the rack towards the shaft.

• Measure the total pinion torque through the whole

stroke of the rack.

1. Using special tool MB991006, rotate the pinion shaft at the

rate of one rotation in 4 to 6 seconds to check the total
pinion torque and the change in torque.

Standard value:
Total pinion torque: 0.8

− 1.9 N⋅m (7.1 − 16.8 in-lb)

[Change in torque: 0.7 N

⋅m (6.2 in-lb) or less]

CAUTION

When adjusting, set at the highest value of the standard
value range.

NOTE: If the total pinion toque cannot be adjusted to the
standard value within the standard range, replace the power
steering gear and linkage assembly.

2. If the total pinion torque or the change in torque is outside

the standard value, loosen the rack support cover once and
retighten it to the specified torque 12

± 2 N⋅m (107 ± 17

in-lb). And then loosen the rack support cover 10 degrees,
and check the pinion torque again.

.

AC001009 AB

MB991204

13DB061A

MB991006

RACK SUPPORT

COVER

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-41

>>N<< STEERING GEAR WASHER (TAB
WASHER)/STEERING TIE ROD INSTALLATION

After installing the tie rod to the rack, fold tab washer end (two
locations) to tie rod notch.

.

>>O<< STEERING GEAR BAND (BELLOWS
BAND) INSTALLATION

1. Turn the adjusting bolt of special tool MB991561 to adjust

the opening dimension (W) to the standard value.

NOTE: The dimension (W) is adjusted by approximately 0.7
mm (0.03 inch) per one turn.

NOTE: Do not turn the adjusting bolt more than one turn.

Standard value (W): 1.9 mm (0.07 inch)
<When more than 1.9 mm (0.07 inch)>: Screw in the
adjusting bolt.
<When less than 1.9 mm (0.07 inch)>: Loosen the
adjusting bolt.

CAUTION

• Hold the rack housing, and use special tool MB991561

to crimp the bellows band securely.

• Crimp the bellows band until special tool MB991561

touches the stopper.

2. Use special tool MB991561 to crimp the bellows band.

3. Check that crimped width (A) is within the standard value.

Standard value (A): 1.4

− 1.8 mm (0.06 − 0.07 inch)

<When more than 1.8 mm (0.07 inch)>: Readjust the
dimension (W) of step (1) to the value calculated by
the following equation, and repeat step (2).
W = 5.5 mm (0.22 inch)

− A [Example: if (A) is 1.9 mm

(0.07 inch), (W) is 3.6 mm (0.14 inch).]
<When less than 1.4 mm (0.06 inch)>: Remove the bel-
lows band, readjust the dimension (W) of step (1) to
the value calculated by the following equation, and
use a new bellows band to repeat steps (2) to (3).
W = 5.5 mm (0.22 inch)

− A [Example: if (A) is 1.3 mm

(0.05 inch), (W) is 4.2 mm (0.17 inch).]

.

ACX01163 AB

ACX01164 AB

W

MB991561

ADJUSTING BOLT

STOPPER

ACX01165 AB

MB991561

ACX01166 AB

A