Overhaul
POWER STEERING GEAR BOX AND LINKAGEDISASSEMBLY AND ASSEMBLY
Disassembly Steps 1-36:
Required Special Tools:
^ MB990927: Installer Adapter
^ MB990938: Bar (Snap-in type)
^ MB990939: Brass Bar
^ MB990996: Lower Arm Bushing Arbor
^ MB991006: Preload Socket
^ MB991120: Needle Bearing Puller
^ MB991152: Dust Cover Installer
^ MB991197: Bar (Long type)
^ MB991199: Oil Seal Installer
^ MB991202: Oil Seal and Bearing Installer
^ MB991203: Oil Seal and Bearing Installer
^ MB991204: Torque Wrench Socket
^ MB991213: Rack Installer
^ MB991317: Seal Ring Installer
^ MB991561: Boot Band Crimping Tool
^ MD998812: Installer Cap
^ MD998813: Installer 100
^ MD998822: Installer Adapter
^ MD998368: Bearing Installer
^ MD999569: Camshaft Oil Seal Installer
LUBRICATION AND SEALING POINTS
DISASSEMBLY SERVICE POINTS
[[A]] STEERING TIE ROD/STEERING GEAR WASHER (TAB WASHER) REMOVAL
Unfold the tab washer which secures the tie rod and rack with a chisel.
[[B]] STEERING GEAR RACK SUPPORT COVER REMOVAL
Using special tool MB991204, remove the rack support cover from the gear box.
[[C]] OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
[[D]] 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.
[[E]] SPECIAL BEARING/OIL SEAL REMOVAL
Using a socket, remove the oil seal and the special bearing from the valve housing simultaneously.
[[F]] STEERING GEAR PISTON CLIP (CIRCLIP) REMOVAL
Use a screwdriver to remove the circlip from slit of the rack stopper.
[[G]] STEERING GEAR RACK REMOVAL
Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time.
[[H]] OIL SEAL REMOVAL
CAUTION
Do not damage oil seal press fitting surface.
Partially pry the oil seal and remove it from the rack bushing.
[[I]] STEERING GEAR PINION BEARING (BALL BEARING) REMOVAL
Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.
[[J]] STEERING GEAR PINION SHAFT UPPER BEARING (NEEDLE ROLLER BEARING) REMOVAL
CAUTION
Do not open special tool MB991120 excessively to prevent damaging housing interior.
Use special tool MB991120 to remove the needle roller 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.
Use a piece of pipe or similar tool to remove the oil seal from the gear housing.
[[L]] STEERING GEAR BUSHING REMOVAL
Use special tools MD998812, MD998813, MD998822 and MD998368 to remove the steering gear bushing.
ASSEMBLY SERVICE POINTS
]]A[[ STEERING GEAR BUSHING INSTALLATION
Use special tools MD999569 and MB990996 to press-fit the steering gear bushing.
]]B[[ OIL SEAL INSTALLATION
1. Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to both sides of the oil seal.
2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing.
]]C[[ STEERING GEAR PINION SHAFT UPPER BEARING (NEEDLE ROLLER BEARING)/STEERING GEAR PINION BEARING (BALL BEARING) INSTALLATION
CAUTION
Press-fit the bearing straight. The valve housing is aluminum, and may become deformed if the bearing is press-fitted on an angle.
1. Apply GENUINE MITSUBISHI POWER STEERING FLUID to the housing, bearing and oil seal press fitting surface.
2. Press fit the needle roller bearing with special tools MB990938 and MB991202.
]]D[[ OIL SEAL/O-RING INSTALLATION
1. Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the outside of the oil seal and O-ring.
2. Use special tool MB990927 to press fit oil seal until it touches the rack bush end.
]]E[[ STEERING GEAR RACK 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 the rack serrations with special tool MB991213.
3. Apply GENUINE MITSUBISHI POWER STEERING FLUID to special tool MB991213.
4. Align the center of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power the cylinder side.
]]F[[ STEERING GEAR BUSHING (RACK BUSHING) INSTALLATION
CAUTION
Do not allow oil seal retainer spring to slip out.
Wrap the rack end with vinyl tape, apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID, and then install the rack bushing and rack stopper.
]]G[[ STEERING GEAR PISTON CLIP (CIRCLIP) INSTALLATION
Insert claw of circlip in a slit of rack stopper. Then set firmly the circlip in a ditch of steering gear housing.
]]H[[ OIL SEAL/SPECIAL BEARING INSTALLATION
Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the outside of the oil seal/special bearing. Using special tools MB990938 and MB991203, press the oil seal/special bearing into the valve housing.
]]I[[ SEAL RING INSTALLATION
Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the seal rings, or press down by hand.
]]J[[ 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 MB991152, press the oil seal into the valve housing.
]]K[[ STEERING GEAR PLUG (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.
]]L[[ STEERING GEAR RACK SUPPORT COVER/STEERING GEAR INNER NUT (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 12 ± 2 Nm (107 ± 17 in-lb).
4. Turn the rack support cover 10 degree angle 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-lb).
]]M[[ 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 4 to 6 seconds to check the total pinion torque and the change in torque.
Standard value:
Total pinion torque: 0.8 - 1.9 Nm (7.1 - 16.8 in-lb)
[Change in torque: 0.7 Nm (6.2 in-lb) 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 standard range, replace the power steering gear and linkage assembly.
2. If the total pinion torque or the change in torque is outside the standard value, loosen the rack support cover once and retighten it to the specified torque 12 ± 2 Nm (107 ± 17 in-lb). And then loosen the rack support cover 10 degrees, and check the pinion torque again.
]]N[[ STEERING GEAR WASHER (TAB WASHER)/STEERING TIE ROD INSTALLATION
After installing the tie rod to the rack, fold tab washer end (two locations) to tie rod notch.
]]O[[ STEERING GEAR BAND (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): 1.9 mm (0.07 inch)
[When more than 1.9 mm (0.07 inch)]: Screw in the adjusting bolt.
[When less than 1.9 mm (0.07 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): 1.4 - 1.8 mm (0.06 - 0.07 inch)
[When more than 1.8 mm (0.07 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 1.9 mm (0.07 inch), (W) is 3.6 mm (0.14 inch).]
[When less than 1.4 mm (0.06 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 1.3 mm (0.05 inch), (W) is 4.2 mm (0.17 inch).]
]]P[[ TIE ROD END ASSEMBLY/STEERING GEAR NUT (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 nuts must be tightened securely only after the steering gear is installed and toe is adjusted.
INSPECTION
RACK
^ Check the rack tooth surfaces for damage or wear.
^ Check the oil seal contact surfaces for uneven wear.
^ Check the rack for bends.
PINION AND VALVE ASSEMBLY
^ Check the pinion gear tooth surfaces for damage or wear.
^ Check for worn or defective seal ring.
BEARING
^ Check for roughness or abnormal noise during bearing operation.
^ Check the bearing for play.
^ Check the needle roller bearings for roller slip-off.
OTHERS
^ Check the cylinder inner surface of the rack housing for damage.
^ Check the boots for damage, cracking or deterioration.
^ Check the rack support for uneven wear or dents.
^ Check the rack bushing for uneven wear or damage.