Mitsubishi Montero (2004+). Manual — part 1163
POWER STEERING GEAR BOX ASSEMBLY
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POWER STEERING
37A-41
>>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
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
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-42
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-43
>>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
POWER STEERING GEAR BOX ASSEMBLY
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POWER STEERING
37A-44
>>N<< TIE ROD END/TIE ROD END JUM NUT
INSTALLATION
Screw in the tie rod end to achieve the right and left length as
illustrated. Lock with the lock nut.
NOTE: Tighten the locknut to the specified torque after install-
ing the gear box assembly onto the body and adjusting the
toe-in.
.
>>O<< GEAR MOUNT RUBBER INSTALLATION
Install the gear mount rubber on the race housing so that the
dimension shown in the illustration can be obtained.
ACX01140AC
57 mm
(2.2 in)
JUM NUT
BELLOWS
END
ACX01168 AB
390 mm
(15.4 in)
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