Mitsubishi Montero (2002-2004). Manual — part 438

POWER STEERING GEAR BOX ASSEMBLY

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POWER STEERING

37A-39

CAUTION

Do not allow oil seal retainer spring to slip out.
3. Wrap the rack end with vinyl tape, apply a coating of

GENUINE MITSUBISHI POWER STEERING FLUID, and
then install the rack bushing and rack stopper.

.

>>E<< CIRCLIP INSTALLATION

CAUTION

Insert the circlip to the rack stopper hole while turning the
rack stopper clockwise.
Insert the circlip to the rack stopper hole through cylinder hole.
Turn the rack stopper clockwise and insert the circlip firmly.

.

>>F<< UPPER OIL SEAL/UPPER BALL BEARING
INSTALLATION
Apply a coating of GENUINE MITSUBISHI POWER STEER-
ING FLUID to the outside of the oil seal. Using special tools
MB990938 and MB991203, press the oil seal into the valve
housing.

.

ACX01157

RACK BUSH

AB

VINYL TAPE

RACK

ACX01158

CIRCLIP

SLOT

SLOT

AB

CIRCLIP

ACX01159AB

MB990925
(MB990938)

MB991203

MB991203

UPPER
OIL SEAL

BEARING

MB990925
(MB990938)

POWER STEERING GEAR BOX ASSEMBLY

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POWER STEERING

37A-40

>>G<< SEAL RING INSTALLATION
Because the seal rings expand after installation, tighten after
installing by using special tool 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 align-
ment surface, the upper surface of the oil seal should
project outward approximately 1 mm (0.04 inch) from the
housing edge surface.
Using special tool MB990941, press the oil seal into the valve
housing.

.

>>I<< END PLUG INSTALLATION

CAUTION

Apply the sealant to the entire threaded part. Ensure that
no excess is squeezed out into the gear housing.
1. Apply 3M

ä AAD Part number 8672, 8679, 8678, 8663, 8661

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.

.

>>J<< RACK SUPPORT COVER/LOCK NUT INSTALLATION

CAUTION

Apply the sealant to the entire threaded part. Ensure that
no excess is squeezed out into the gear housing.
1. Apply 3M

ä AAD Part number 8672, 8679, 8678, 8663, 8661

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

ACX01160 AB

MB991317

ACX01161

HOUSING

AB

OIL
SEAL

APPROXIMATELY
1 mm(0.04 in)

MB991152

ACX01162 AB

END PLUG

END PLUG

POWER STEERING GEAR BOX ASSEMBLY

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POWER STEERING

37A-41

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

to 12

± 2 N⋅m (106 ± 21 in-lb).

3. Turn the rack support cover 10 degree angle

counterclockwise.

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

and then tighten the lock nut to 59

± 10 N⋅m (44 ± 7 ft-lb).

.

>>K<< 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 four to six seconds to check the total
pinion torque and the change in torque.

Standard value:

• Total pinion torque: 0.6 − 1.7 N⋅m (5.3 − 15.0 in-lb)

• [Change in torque: 0.4 N⋅m (3.5 in-lb) or less]

CAUTION

When adjusting, set at the highest value of the standard
value range.
2. If the total pinion torque or the change in torque is outside

the standard value, move the rack support cover 0

− 30

degree angle, and adjust the pinion torque again.
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 nec-
essary.

.

>>L<< TAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold tab washer end (two
locations) to tie rod notch.

.

AC000666 AB

MB991204

AC000665 AB

MB991006

ACX01163 AB

POWER STEERING GEAR BOX ASSEMBLY

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POWER STEERING

37A-42

>>M<< 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): 2.9 mm (0.11 inch)
<When more than 2.9 mm (0.11 inch)>: Screw in the
adjusting bolt.
<When less than 2.9 mm (0.11 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): 2.4

− 2.8 mm (0.09 − 0.11 inch)

<When more than 2.8 mm (0.11 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 2.9 mm (0.11 inch), (W) is 2.6 mm
(0.10 inch).]
<When less than 2.4 mm (0.09 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 2.3 mm (0.09 inch), (W) is 3.2 mm
(0.13 inch).]

.

ACX01164 AB

W

MB991561

ADJUSTING BOLT

STOPPER

ACX01165 AB

MB991561

ACX01166 AB

A