Mitsubishi Lancer Evolution IX. Manual — part 325
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-25
DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER
REMOVAL
AC103692 AF
MB991621
Using the following special tool piston driver
(MB991621), remove the rack support cover from the
steering gear.
<<B>> LOWER OIL SEAL/PINION AND
VALVE ASSEMBLY REMOVAL
ACX01143 AB
Using a plastic hammer, gently tap the pinion to
remove it.
<<C>> 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.
<<D>> 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.
<<E>> 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.
<<F>> RACK STOPPER/RACK
BUSHING/OIL SEAL/O-RING/RACK
ASSEMBLY REMOVAL
ACX01147 AB
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-26
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.
<<G>> LOWER BEARING REMOVAL
ACX01149
MB990939
Lower bearing
AC
Valve housing
Use a brass bar or special tool brass bar
(MB990939) to remove the lower bearing from the
valve housing.
<<H>> NEEDLE BEARING REMOVAL
CAUTION
Do not open special tool 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 valve housing.
<<I>> 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
1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
AC100260 AF
MB991197
Oil seal
MB991199
Gear housing
2. Using the following special tools, press the oil seal
into the rack housing.
• Bar (long type) (MB991197)
• Oil seal installer (MB991199)
>>B<< NEEDLE BEARING/LOWER
BEARING INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing
and bearing press fitting surface.
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-27
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
AE
MB990938
2. Press fit needle bearing/lower bearing with the
following special tools.
• Bar (snap-in type) (MB990938)
• Oil seal and bearing installer (MB991202)
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not close the vent hole in the rack with
grease.
ACX01154 AB
Seal ring and O-ring
Vent hole
1. Apply a coating of repair kit grease to the rack
teeth face.
ACX01155
MB991214
AH
Oil seal
2. Cover rack serrations with the following special
tool oil seal protector (MB991214).
3. Apply ATF DEXRON III or DEXRON II to special
tool, and to the outer surface of the seal ring and
the O-ring.
4. Align the centre of the oil seal with the rack to
prevent the retainer spring from slipping. Slowly
insert the rack from power cylinder side.
>>D<< OIL SEAL/RACK BUSHING
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 special tool installer
adapter (MB990927), press in the oil seal until it is
flush with the bushing end face.
AC100261AC
Rack
Plastic tape
Rack bushing
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
AB
Circlip
Slot
POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING
37-28
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
the following special tools, press the upper oil
seal/upper bearing into the valve housing.
• Bar (snap-in type) (MB990938)
• Oil seal and bearing installer (MB991203)
>>G<< SEAL RINGS 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
ACX01161
Housing
AC
Oil
seal
Approximately
1 mm
MB990941
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.
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.8661 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.8661 or equivalent
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