Mitsubishi Outlander (2003+). Manual — part 292

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-27

>>F<< UPPER OIL SEAL/UPPER BEARING
INSTALLATION

Apply a coating of ATF DEXRON III or DEXRON II to
the outside of the upper oil seal/upper bearing. Using
the following special tools, press the upper oil seal/
upper bearing into the valve housing.

œ

MB990938: Bar (Snap-in type)

œ

MB991203: Oil Seal and Bearing Installer

>>G<< SEAL RING INSTALLATION

Because the seal rings expand after installation,
tighten after installing by using special tool seal ring
installer (MB991317) to compress the rings, or press
down by hand.

>>H<< LOWER OIL SEAL INSTALLATION

CAUTION

To eliminate a seal malfunction at the valve
housing alignment surface, the upper surface of
the oil seal should project outward approximately
1 mm from the housing edge surface.
Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve
housing.

>>I<< END PLUG INSTALLATION

1. Apply specified sealant to the threaded part of the

end plug.

Specified sealant:
3M ATD Part No.8661, 8663 or equivalent

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

places by using a punch.

>>J<< RACK SUPPORT COVER/JAM NUT
INSTALLATION
1. Position the rack at its centre.
2. Apply specified sealant to the threaded part of the

rack support cover.

Specified sealant:
3M ATD Part No.8661, 8663 or equivalent

ACX01159AC

MB990938

MB991203

Oil seal

MB991203

Bearing

MB990938

ACX01160 AB

MB991317

ACX01161

Housing

AC

Oil
seal

Approximately
1 mm

MB990941

ACX01162 AB

End plug

End plug

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-28

3. Use special tool rack support cover wrench

(MB991621) to tighten the rack support cover to
23

–

2 N

¼

m.

4. Turn the rack support cover 30

•

counterclockwise.

5. Use the special tool to hold the rack support

cover, and then tighten the jam nut to 59

–

10

N

¼

m.

>>K<< TOTAL PINION TORQUE ADJUSTMENT

CAUTION

œ

Be sure there is no ratcheting or catching
when operating the rack towards the shaft.

œ

Measure the total pinion torque through the
whole stroke of the rack.

1. Using special tool preload socket (MB991006),

rotate the pinion shaft at the rate of one rotation in
four to six seconds to check the total pinion torque
and the change in torque.

Standard value:
Total pinion torque: 0.7

-

1.6 N

¼

m

[Change in torque: 0.4 N

¼

m 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 specified return
angle, check the rack support cover components
and replace any parts if necessary.

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

outside the standard value, move the rack support
cover 0

-

30

•

, and adjust the pinion torque again.

>>L<< TAB WASHER/TIE ROD INSTALLATION

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

>>M<< BELLOWS BAND INSTALLATION

1. Turn the adjusting bolt of special tool boot band

crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.

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

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

Standard value (W): 2.9 mm
<When more than 2.9 mm>: Screw in the
adjusting bolt.
<When less than 2.9 mm>: Loosen the
adjusting bolt.

AC100273

MB991621

AC

AC100274 AB

MB991006

ACX01163 AB

ACX01164 AB

W

MB991561

Adjusting bolt

Stopper

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-29

CAUTION

œ

Hold the rack housing, and use special tool to
crimp the bellows band securely.

œ

Crimp the bellows band until special tool
touches the stopper.

2. Use special tool boot band crimping tool

(MB991561) to crimp the bellows band.

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

standard value.

Standard value (A): 2.4

-

2.8 mm

<When more than 2.8 mm>: Readjust the
dimension (W) of step (1) to the value
calculated by the following equation, and
repeat step (2).
W = 5.5 mm

-

A [Example: if (A) is 2.9 mm,

(W) is 2.6 mm.]
<When less than 2.4 mm>: Remove the
bellows 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

-

A [Example: if (A) is 2.3 mm,

(W) is 3.2 mm.]

>>N<< TIE ROD END/JAM NUT INSTALLATION

Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the jam nut.

NOTE: The jam nuts must be tightened securely only
after the steering gear is installed to the vehicle and
toe-in is adjusted.

>>O<< GEAR MOUNTING RUBBER
INSTALLATION

Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.

ACX01165 AB

MB991561

ACX01166 AB

A

AC001011 AH

Jam nut

Edge of bellows
assembly groove

186 mm

AC100275AB

220 mm

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-30

TIE ROD END BALL JOINT DUST COVER
REPLACEMENT

M1372008200305

If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:

1. Apply specified grease to the lip and inside of the

dust cover.

Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent

2. Drive in the dust cover with special tool front axle

base (MB990776) until it is fully seated.

3. Check the dust cover for cracks or damage by

pushing it with your finger.

AC001012AB

MB990776