Mitsubishi L200. Manual — part 482
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-31
<<E>> SEAL RING REMOVAL
CAUTION
When cutting the seal ring, be careful not to dam-
age the pinion and valve assembly or the rack.
ACX01144 AB
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
<<F>> UPPER BEARING/UPPER OIL SEAL
REMOVAL
ACX01145AC
Socket
Using a socket, remove the oil seal and the ball bear-
ing from the valve housing simultaneously.
<<G>> CIRCLIP REMOVAL
CAUTION
If the rack stopper is first turned anticlockwise,
the circlip will get caught in the slot in the hous-
ing and the rack stopper will not turn.
ACX01146 AB
Circlip
Rack stopper
1. Turn the rack stopper clockwise until the end of
the circlip comes out of the slot in the rack
housing.
2. Turn the rack stopper anticlockwise to remove the
circlip.
<<H>> RACK STOPPER/RACK BUSHING
ASSEMBLY/O-RING/OIL SEAL/RACK ASSEMBLY
REMOVAL
ACX01147 AB
1. Pull out the rack slowly. Take out the rack stopper
and the rack bushing at the same time.
CAUTION
Do not damage the oil seal press fitting surface.
ACX01148 AB
Rack bushing
2. Partially bend the oil seal and remove it from the
rack bushing.
<<I>> LOWER BEARING REMOVAL
ACX01149
MB990939
Lower bearing
AC
Valve housing
Use a brass bar or special tool brass bar
(MB990939) to remove the ball bearing from the gear
housing.
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-32
<<J>> NEEDLE BEARING REMOVAL
CAUTION
Do not open special tool needle bearing puller
(MB991120) excessively to prevent damaging
housing interior.
ACX01150 AB
Valve housing
MB991120
Needle
bearing
Use special tool needle bearing puller (MB991120) to
remove the needle bearing from the rack housing.
<<K>> OIL SEAL REMOVAL
CAUTION
Be careful not to damage the inner surface of the
rack cylinder of the gear housing.
AC100259
Oil seal
Pipe or similar tool
Gear housing
AB
Use a piece of pipe or similar tool to remove the oil
seal from the gear housing.
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
AC802691
AD
Piston
Rack assembly
Oil seal
Plastic tape
1. Wrap the rack assembly teeth face with plastic
tape, and apply a coating of ATF DEXRON III or
DEXRON II.
2. Insert the oil seal in rack assembly, and move to
the piston.
>>B<< NEEDLE BEARING/LOWER BEARING
INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing,
bearing and oil seal press fitting surface.
CAUTION
Press-fit straight. The valve housing is alumin-
ium, and may become deformed if press-fit on an
angle.
ACX01153
Needle
bearing
MB990938
MB991202
MB991202
Lower
bearing
AH
MB990938
2. Press fit needle bearing with following special
tools.
• Bar (snap-in type) (MB990938)
• Oil seal and bearing installer (MB991202)
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not plug the vent hole in the rack with grease.
AC802691
AE
Seal ring and o-ring
Vent hole
Oil seal
1. Removal the plastic tape, and apply a coating of
multipurpose grease to the rack teeth face.
2. Apply a coating of ATF DEXRON III or DEXRON II
to the outer surface of the seal ring and the O-
ring.
3. Slowly insert the rack from power cylinder side.
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-33
>>D<< OIL SEAL/O-RING/RACK BUSHING
ASSEMBLY INSTALLATION
ACX01156 AE
Oil seal
O-ring
MB990927
Rack
bushing
1. Apply ATF DEXRON III or DEXRON II to the outer
surface of the oil seal. Using the special tool
installer adapter (MB990927), press in the oil seal
until it is flush with the bushing end face.
AC500042 AC
Rack bushing
Vinyl tape
Rack
2. Apply ATF DEXRON III or DEXRON II to the oil
seal inner surface and the O-ring.
3. Wrap the rack end with plastic tape, and push the
rack bushing onto the rack.
>>E<< CIRCLIP INSTALLATION
CAUTION
Insert the circlip to the rack stopper hole while
turning the rack stopper clockwise.
ACX01158
Circlip
Slot
AD
Circlip
Slot
Rack stopper
Insert the circlip to the rack stopper hole through cyl-
inder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
>>F<< UPPER OIL SEAL/UPPER BEARING
INSTALLATION
ACX01159AC
MB990938
MB991203
Oil seal
MB991203
Bearing
MB990938
Apply a coating of ATF DEXRON III or DEXRON II to
the outside of the upper oil seal/upper bearing. Using
following special tools, press the upper oil seal/upper
bearing into the valve housing.
• MB990938: Bar (Snap-in type)
• MB991203: Oil Seal and Bearing Installer
>>G<< SEAL RING INSTALLATION
ACX01160 AB
MB991317
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 hous-
ing alignment surface, the upper surface of the
oil seal should project outward approximately 1
mm from the housing edge surface.
ACX01161
Housing
AC
Oil
seal
Approximately
1 mm
MB990941
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-34
Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve hous-
ing.
>>I<< END PLUG INSTALLATION
ACX01162 AB
End plug
End plug
1. Apply specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No. 8663 or equivalent
2. Secure the threaded portion of the end plug at two
places by using a punch.
>>J<< RACK SUPPORT COVER/LOCK 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. 8663 or equivalent
AC100273 AO
MB991621
MB992351
<2WD (Except High rider)>
<2WD (High rider), 4WD>
3. Use special tool rack support cover wrench
(MB991621) <2WD (except High rider)>, torque
wrench socket (MB992351) <2WD (High rider),
4WD> to tighten the rack support cover.
4. Use the special tools to hold the rack support
cover, and then tighten the lock nut to 59
± 10
N
⋅m.
>>K<< TOTAL PINION TORQUE ADJUSTMENT
CAUTION
• Be sure there is no ratcheting or catching
when operating the rack towards the shaft.
•
AC100274AB
MB991006
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: 0.6
− 1.7 N⋅m
[Torque fluctuation: 0.4 N
⋅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<< TIE ROD INSTALLATION
CAUTION
Do not tighten the vise strongly in order not to
damage the rack bar.
AC700957AD
Tie rod
Steering gear
Rack bar
Cloth
1. Wrap rack bar with cloth in order not to damage,
and fix the rack bar with a vise.
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