Power Steering Gear Box and Linkage Disassembly and Reassembly

DISASSEMBLY AND ASSEMBLY

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]] TAB WASHER REMOVAL

1. Move the bellows and pull the rack bar toward arrow direction.

2.
CAUTION:

- Do not tighten the vise strongly in order not to damage the tie rod.

- Do not make an impact to the rack bar.

Fix the tie-rod ball joint part with a vise.
3. Use a screw driver and hammer to lift right and left tab washer caulked edges.

[[B]] TIE-ROD REMOVAL

1.
CAUTION:
Do not tighten the vise strongly in order not to damage the rack bar.

Wrap rack bar with cloth in order not to damage, and fix the rack bar with a vise.
2. Use the special tool MB991204 to remove the tie-rod.

[[C]] JAM NUT/ RACK SUPPORT COVER REMOVAL

1. Using special tool MB992249, remove the jam nut from the gear box.

2. Using special tool MB991204, remove the rack support cover from the gear box.

[[D]] LOWER OIL SEAL/ PINION AND VALVE ASSEMBLY REMOVAL

Using a plastic hammer, gently tap the pinion to remove it.

[[E]] 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.

[[F]] SPECIAL BEARING/ UPPER OIL SEAL REMOVAL

Using a socket, remove the oil seal and the special bearing from the valve housing simultaneously.

[[G]] CIRCLIP REMOVAL

Use a screwdriver to remove the circlip from slit of the rack stopper.

[[H]] RACK ASSEMBLY REMOVAL

Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time.

[[I]] OIL SEAL REMOVAL

CAUTION:
Do not damage oil seal press fitting surface.

Partially prize the oil seal and remove it from the rack bushing.

[[J]] LOWER BALL BEARING REMOVAL

Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.

[[K]] 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.

[[L]] 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.

[[M]] 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. The projections of the bushing should be positioned as illustrated.

]]B[[ OIL SEAL INSTALLATION

1. Wrap the rack assembly teeth face with plastic tape, and apply a coating of Genuine MITSUBISHI power steering fluid.
2. Insert the oil seal in rack assembly, and move to the piston.

]]C[[ NEEDLE ROLLER BEARING/ LOWER 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[[ RACK ASSEMBLY INSTALLATION

1.
CAUTION:
Do not plug the vent hole in the rack with grease.

Removal the plastic tape, and apply a coating of multipurpose grease to the rack teeth face.
2. Apply a coating of Genuine MITSUBISHI power steering fluid to the outer surface of the seal ring and the O-ring.
3. Slowly insert the rack from power cylinder side.

]]F[[ 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[[ 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[[ UPPER 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[[ 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 MB991152, press the oil seal into the valve housing.

]]K[[ END PLUG INSTALLATION

1. Apply 3MTM 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[[ RACK SUPPORT COVER/ JAM NUT INSTALLATION

1. Position the rack at its center.

2. Apply 3MTM 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.
12± 2Nm (106± 17 in-lb)
4. Turn the rack support cover 10 degree angle counterclockwise.
5. Use special tool MB991204 and special tool MB992249 to hold the rack support cover, and then tighten the jam nut.
59± 10Nm (44± 7 ft-lb)

]]M[[ TOTAL PINION TORQUE ADJUSTMENT

1.
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.

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 - 1.9Nm (7.1 - 16.8 in-lb)
[Change in torque: 0.7Nm (6.2 in-lb) or less]
2.
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.

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 (106 ± 17 in-lb). And then loosen the rack support cover 10 degrees, and check the pinion torque again.

]]N[[ TAB WASHER INSTALLATION

1.
CAUTION:

- Do not tighten the vise strongly in order not to damage the tie rod.

- Do not make an impact to the rack bar.

Fix the tie rod ball joint part with a vise.
2. Use a hammer to caulk the right and left tab washer at two places.

]]O[[ TIE-ROD INSTALLATION

1.
CAUTION:
Do not tighten the vise strongly in order not to damage the rack bar.

Wrap rack bar with cloth in order not to damage, and fix the rack bar with a vise.
2. Use the special tool MB992249 to install the tie rod.
Tightening torque: 84± 14Nm (62± 10 ft-lb)

]]P[[ BELLOWS BAND INSTALLATION

1.
CAUTION:

- Hold the rack housing, and use special tool bellows band crimping tool (MB992209) to crimp the bellows band securely.
- Crimp the bellows band until special tool (MB992209) touches the stopper.

Use special tool (MB992209) to crimp the bellows band.

2. Check that crimped width (A) is within the standard value.
Standard value (A): 1.4 - 1.8 mm (0.06 -0.07 in)

]]Q[[ TIE-ROD END / 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.