Mitsubishi Lancer. Manual — part 196

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-32

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

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.

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-33

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

AC100273

MB990607 <Invite>
MB991621 <Intense>

AJ

3. Use the following special tool to tighten the rack

support cover to 23

± 2 N⋅ m.

• Torque wrench socket (MB990607) <Invite>

• Piston driver (MB991621: <Intense>

4. Turn the rack support cover 30

° anticlockwise.

5. Use the special tool 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
4 to 6 seconds to check the total pinion torque and
the change in torque.

Standard value:

Total pinion torque: 0.8

− 2.1 N⋅ m <Invite>

[Change in torque: 0.6 N

⋅ m or less]

Total pinion torque: 0.7

− 2.1 N⋅ m <Intense>

[Change in torque: 0.6 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<< TAB WASHER/TIE ROD
INSTALLATION

ACX01163 AB

After installing the tie rod to the rack, fold tab washer
end (two locations) to tie rod notch.

>>M<< BELLOWS BAND INSTALLATION

ACX01164 AB

W

MB991561

Adjusting bolt

Stopper

1. Turn the adjusting bolt of special tool boot band

crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-34

NOTE: The dimension (W) is adjusted by approxi-
mately 0.7 mm per one turn.
NOTE: Do not turn the adjusting bolt more than
one turn.

Standard value (W): 2.9 mm
<When more than 2.9 mm>: Screw in the
adjusting bolt.
<When less than 2.9 mm>: Loosen the
adjusting bolt.

CAUTION

• Hold the rack housing, and use special tool to

crimp the bellows band securely.

•

ACX01165 AB

MB991561

Crimp the bellows band until special tool
touches the stopper.

2. Use special tool boot band crimping tool

(MB991561) to crimp the bellows band.

ACX01166 AB

A

3. Check that crimped width (A) is within the

standard value.

Standard value (A): 2.4

− 2.8 mm

<When more than 2.8 mm>: Readjust the
dimension (W) of step (1) to the value calcu-
lated by the following equation, and repeat
step (2).

W = 5.5 mm

− A [Example: if (A) is 2.9 mm,

(W) is 2.6 mm.]
<When less than 2.4 mm>: Remove the bel-
lows band, readjust the dimension (W) of
step (1) to the value calculated by the follow-
ing equation, and use a new bellows band to
repeat steps (2) to (3).
W = 5.5 mm

− A [Example: if (A) is 2.3 mm,

(W) is 3.2 mm.]

>>N<< TIE ROD END/LOCK NUT
INSTALLATION

AC001011AM

Lock nut

Edge of bellows
assembly groove

180 mm

Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut.
NOTE: The lock nuts must be tightened securely
only after the steering gear is installed to the vehicle
and toe-in is adjusted.

>>O<< GEAR MOUNTING RUBBER
INSTALLATION

AC100275AB

220 mm

Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.

POWER STEERING OIL PUMP ASSEMBLY

POWER STEERING

37-35

TIE ROD END BALL JOINT DUST COVER
REPLACEMENT

M1372008200327

If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:

AC001012AB

MB990776

1. Apply specified grease to the lip and inside of the

dust cover.

Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent

2. Drive in the dust cover with special tool front axle

base (MB990776) until it is fully seated.

3. Check the dust cover for cracks or damage by

pushing it with your finger.

POWER STEERING OIL PUMP ASSEMBLY

REMOVAL AND INSTALLATION

M1372005200298

Pre-removal Operation
• Power Steering Fluid Draining (Refer to

P.37-13

).

Post-installation Operation
• Power Steering Fluid Supplying and Bleeding (Refer to

P.37-14

).

• Drive Belt Tension Check (1300, 1600: refer to GROUP

11A, On-vehicle Service

− Drive Belt Tension Check

P.11A-7

/2000: refer to GROUP 11C, On-vehicle Service

−

Drive Belt Tension Check

P.11C-7

).

<1300, 1600>

AC209708

8

7

1

2

3

4

5

6

57 ± 7 N·m

40 ± 4 N·m

22 ± 4 N·m

N

9

40 ± 5 N·m

AC