Overhaul
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY AND ASSEMBLY
LUBRICATION AND SEALING POINTS
DISASSEMBLY SERVICE POINTS
[[A]] RACK SUPPORT COVER REMOVAL
Using special tool MB991204, remove the rack support cover from the gear box.
[[B]] LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL
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 damage the pinion and valve assembly or the rack.
Cut the seal ring and remove it from the pinion and valve assembly and the rack.
[[D]] UPPER BEARING/UPPER OIL SEAL REMOVAL
Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
[[E]] CIRCLIP REMOVAL
CAUTION: If the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.
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 counterclockwise to remove the circlip.
[[F]] RACK STOPPER/RACK BUSHING/OIL SEAL/O-RING/RACK ASSEMBLY REMOVAL
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.
2. Partially bend the oil seal and remove it from the rack bushing.
[[G]] LOWER BEARING REMOVAL
Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.
[[H]] NEEDLE BEARING REMOVAL
CAUTION: To prevent damaging housing interior, do not open special tool MB991120 excessively.
Use special tool MB991120 to remove the needle roller bearing from the rack housing.
[[I]] OIL SEAL REMOVAL
CAUTION: Be careful not to damage the inner surface of the rack cylinder of the gear housing.
Use a piece of pipe or similar tool to remove the oil seal from the gear housing.
ASSEMBLY SERVICE POINTS
]]A[[ OIL SEAL INSTALLATION
1. Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the both sides of the oil seal.
2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing.
]]B[[ NEEDLE BEARING LOWER BEARING INSTALLATION
1. Apply GENUINE MITSUBISHI POWER STEERING FLUID to housing, bearing and oil seal press fitting surface.
CAUTION: Press-fit straight. The valve housing is aluminum, and may become deformed if press-fit on an angle.
2. Press fit needle roller bearing with special tools MB990938 and MB991202.
]]C[[ RACK ASSEMBLY INSTALLATION
CAUTION: Do not close the vent hole in the rack with grease.
1. Apply a coating of multipurpose grease to the rack teeth face.
2. Cover rack serrations with special tool MB991214.
3. Apply GENUINE MITSUBISHI POWER STEERING FLUID to special tool MB991214.
4. Align the center of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side.
]]D[[ 01L SEAL/RACK BUSHING INSTALLATION
1. Apply GENUINE MITSUBISHI POWER STEERING FLUID to the outer surface of the oil seal. Using special tool MB990927, press in the oil seal until it is flush with the bushing end face.
2. Apply GENUINE MITSUBISHI POWER STEERING FLUID 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.
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 BEARING INSTALLATION
Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the outside of the upper oil seal/upper bearing. Using special tools MB990938 and MB991203, press the upper oil seal/upper bearing into the valve housing.
]]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 alignment 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
1. Apply 3M(TM) AAD Part number 8661, 8663,8672, 8678, 8679 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/JAM NUT INSTALLATION
1. Position the rack at its center.
2. Apply 3M(TM) AAD Part number 8661, 8663, 8672, 8678, 8679 or equivalent to the threaded part of the rack support cover.
3. Use special tool MB991204 to tighten the rack support cover to 23 ± 2 Nm (17 ± 1 ft. lbs.)
4. Turn the rack support cover 30 degrees counterclockwise.
5. Use special tool MB991204 to hold the rack support cover. and then tighten the jam nut to 59 ± 10 Nm (44 ± 7 ft. lbs.).
]]K[[ TOTAL PINION TORQUE ADJUSTMENT
CAUTION:
^ Be sure there is no ratcheting or catching when operating 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: 0.8 - 1.8 Nm (7.1 - 15.9 inch lbs.)
[Change in torque: 0.49 Nm (4.3 inch lbs.) 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 degrees, and adjust the pinion torque again.
NOTE: If the tote/ 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.
]]L[[ GEAR MOUNTING RUBBER INSTALLATION
Install the gear mounting rubber to the rack housing so that the distance is as shown in the illustration.
]]M[[ TAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack fold the tab washer end (two locations) to tie rod notch.
]]N[[ 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 bellows 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).]
]]O[[ TIE ROD END/JAM NUT INSTALLATION
Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut.
NOTE: The locking nut must be tightened securely only after the power steering gear box and linkage are installed to the vehicle and toe-in is adjusted.
TIE ROD END BALL JOINT DUST COVER REPLACEMENT
If the dust cover is damaged accidentally during service work replace the dust cover as follows:
1. Apply grease to the lip and inside of the dust cover.
2. Drive in the dust cover with special tool MB990776 until it is fully seated.
3. Check the dust cover for cracks or damage by pushing it with your finger.