Mitsubishi Montero (1998+). Manual — part 291
Fig. 3: Exploded View Of Power Recirculating Ball Steering Gear
Courtesy of Mitsubishi Motor Sales of America.
Inspection
Check mainshaft for wear and damage. Check tooth surface of
cross shaft and rack piston for wear and damage. Check contact part of
adjusting bolt for uneven wear. Check dust seal, oil seal and "O"
rings for wear and damage.
Reassembly
1) Install NEW cross shaft lower "U" packing (if removed).
Press lower cross shaft oil seal into gearbox housing. See Fig. 3.
Press bearing and oil seal into top cover. Install bearing race and
"O" ring.
2) Apply transmission fluid to seal ring contact areas on
mainshaft, and install seal rings firmly into valve grooves. Wrap
serrated part of mainshaft with vinyl tape. Mount valve body to valve
housing. Install cage and align hole in cage with channel in
mainshaft. Install bearing race and insert balls.
3) Install mainshaft into valve housing while pressing on
bearing race to prevent balls from falling out. Using spanner wrench,
install lock nut and tighten until it contacts bearing race.
4) Tighten lock nut while measuring mainshaft endplay using
dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch
to crimp circumference of lock nut. Ensure mainshaft rotates freely.
5) Apply transmission fluid to "O" ring and piston seal ring,
and install into gearbox housing. Install rack piston until it
contacts edge of mainshaft. Rotate mainshaft to align ball raceway
with insertion hole. Install 19 balls.
NOTE: Insert balls so no clearance exists between balls.
6) Place remaining 7 balls in circulator and install
circulator to rack piston. Install circulator holder. Install NEW
cross shaft upper "U" packing (if removed). Install upper cross shaft
"O" ring. Apply transmission fluid to rack piston seal ring and insert
valve housing. Rotate mainshaft until rack piston is centered (neutral
position).
7) Install adjusting plate so beveled part is facing upward.
Using a feeler gauge, measure clearance between adjusting bolt and
cross shaft. If clearance is greater than .002" (.05 mm), replace with
appropriate adjusting plate.
8) Apply multipurpose grease to seal surface of "U" packing.
Apply transmission fluid to cross shaft teeth and side cover "O" ring.
Install cross shaft to side cover, and temporarily tighten adjusting
bolt lock nut.
CAUTION: DO NOT rotate side cover during installation, or damage to
cross shaft oil seal may result.
9) Apply transmission fluid to rack piston teeth and shaft
areas. Apply multipurpose grease to oil seal lip. Install side cover
assembly (with cross shaft) to gearbox.
10) Position mainshaft in straight-ahead position. While
turning adjusting bolt, measure mainshaft combined starting torque
using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.
Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center
reading should be 2 INCH lbs. (.2 N.m) higher than reading at either
end.
11) Tighten adjusting bolt lock nut to specification. See
TORQUE SPECIFICATIONS. Install pitman arm with mating marks aligned.
POWER STEERING PUMP
Disassembly
1) Remove suction connector bolts. Mount pump in a soft-jawed
vise. Remove pump cover bolts and cover. Using a plastic mallet, tap
pulley assembly shaft from pump housing. See Fig. 4.
2) Remove cam ring, vanes, shaft assembly and "O" rings.
Remove snap ring from shaft assembly. Remove collar, rotor and side
plate from shaft.
3) Pry oil seal out of housing. Remove pressure connector.
Remove flow control valve assembly, flow control spring and 2 "O"
rings. DO NOT disassemble flow control valve assembly.
Fig. 4: Exploded View Of Power Steering Pump
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Inspect pump shaft oil seal lip and bushing end for
damage. Inspect groove of rotor vane and cam surface for stepped wear.
Check vane for damage. Install vane into rotor groove. Measure
clearance between vane and rotor groove. If clearance exceeds .0024"
(.061 mm), replace entire assembly.
2) Check ring and rotor sides for damage. Replace entire
assembly if any damage is present. Check sliding surfaces of control
valve for obstructions. Replace parts as required. If control valve is
replaced, always use valve with same identification mark as one being
replaced. Check power steering fluid pressure.
Reassembly
1) Lubricate "O" rings and internal pump components with ATF
before reassembly. Install flow control valve spring and control valve
in housing.
2) Install and tighten pressure connector. Depress control
valve to check for smooth operation. Apply grease to lip of oil seal.
Install oil seal into pump body. Install pulley assembly into pump
body.
3) Install rotor to pulley assembly with punch mark at pump
cover side. Install snap ring. Lift rotor to ensure that snap ring is
in countersunk part of shaft. Align cam ring dowel holes and install
cam ring with punch mark on pump body side.
4) Apply transmission fluid to vanes, and install vanes onto
rotor with rounded edges outward. Install "O" ring, cam case and pump
cover. Install and tighten suction connector.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Adjusting Bolt Lock Nut . . . . . . . . . 27 (37)
Idler Arm Bracket-To-Frame Bolt & Nut
Montero . . . . . . . . . . . 40-47 (54-64)
Montero Sport . . . . . . . . . . . 43 (59)
Idler Arm-To-Bracket Lock Nut . . . . . . . . 101 (44)
Oil Pump Cover Bolts . . . . . . . . . ... 15 (20)
Pitman Arm-To-Cross Shaft Nut
Montero . . . . . . . . . . 108-123 (146-176)
Montero Sport . . . . . . . . .. 108-123 (147-167)
Pressure Hose In-Line Fitting
Montero . . . . . . . . . . . . .. 25 (34)
Montero Sport . . . . . . . . . . . 16 (22)
Relay Rod-To-Idler Arm Nut . . . . . . . . . 33 (44)
Relay Rod-To-Pitman Arm Nut . . . . . . . . 33 (44)
Side Cover Bolts
Montero . . . . . . . . . . . . .. 36 (49)
Montero Sport . . . . . . . . . .. 41-47 (50-64)
Steering Gear Hose Fittings . . . . . . . . 11 (15)
Steering Gear-To-Frame Bolts . . . . . . . 40-47 (54-64)
Tie Rod Adjusting Sleeve Lock Nuts . . . . . . . 69 (93)
Tie Rod End Castle Nuts . . . . . . . . . 33 (44)
Valve Housing Bolts
Montero . . . . . . . . . . . . .. 36 (49)
Montero Sport . . . . . . . . . .. 41-47 (56-64)
Valve Housing Lock Nut . . . . . . . . . . . ( 1)
(1) - Tighten lock nut until it contacts bearing race.
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