DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. Steering bushing 2. Feed pipe 3. O-ring 4. Clip >>M<< 5. Bellows band 6. Bellows <<A>> >>L<< 7. Tie rod >>K<< · Total pinion torque adjustment >>J<< 8. Lock nut <<B>> >>J<< 9. Rack support cover 10. Spacer 11. Support spring 12. Rack support >>I<< 13. End plug 14. Lock nut 15. Dust cover 16. Valve housing assembly <<C>> >>H<< 17. Lower oil seal <<C>> 18. Pinion and valve assembly <<D>> >>G<< 19. Seal ring <<E>> >>F<< 20. Upper bearing <<E>> >>F<< 21. Upper oil seal 22. Valve housing <<F>> >>E<< 23. Circlip <<G>> 24. Rack stopper <<G>> >>D<< 25. Rack bushing assembly <<G>> >>D<< 26. O-ring <<G>> >>D<< 27. Oil seal <<G>> >>C<< 28. Rack assembly <<D>> 29. Seal ring 30. O-ring <<H>> >>B<< 31. Lower bearing <<I>> >>B<< 32. Needle bearing <<J>> >>A<< 33. Oil seal 34. Gear housing

LUBRICATION AND SEALING POINTS

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 rack bar. Wrap rack bar with cloth in order not to damage, and fix the rack bar with a vise. 3.Use the special tool variable spanner (MB992249) to remove the tie rod.

Using special tool torque wrench socket (MB992351), remove the rack support cover from the steering gear.

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

Cut the seal ring and remove it from the pinion and valve assembly or the rack.

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

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 anti-clockwise to remove the circlip.

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

2. caution Do not damage the oil seal press fitting surface. Partially bend the oil seal and remove it from the rack bushing.

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

Use special tool needle bearing puller (MB991120) to remove the needle bearing from the rack housing.

Use a piece of pipe or similar tool to remove the oil seal from the gear housing.

1.Wrap the rack assembly teeth face with plastic tape, and apply a coating of MITSUBISHI MOTORS GENUINE PSF (Power Steering Fluid) or DEXRON III, DEXRON II. 2.Insert the oil seal in rack assembly, and move to the piston.

2. caution Press-fit straight. The valve housing is aluminium, and may become deformed if press-fit on an angle. Press fit needle bearing with following special tools. Bar (snap-in type) (MB990938) Installer (MB991146)

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 repair kit grease to the outer surface of the seal ring and the O-ring. 3.Slowly insert the rack from power cylinder side.

1.Apply MITSUBISHI MOTORS GENUINE PSF (Power Steering Fluid) or DEXRON III, DEXRON II to the outer surface of the oil seal. Using the special tool installer adapter (MB991118), press in the oil seal until it is flush with the bushing end face.

2.Apply MITSUBISHI MOTORS GENUINE PSF (Power Steering Fluid) or DEXRON III, 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.

Insert the circlip to the rack stopper hole through cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly.

Apply a coating of MITSUBISHI MOTORS GENUINE PSF (Power Steering Fluid) or DEXRON III, DEXRON II to the outside of the upper oil seal/upper bearing. Using following special tools, press the upper oil seal/upper bearing into the valve housing. MB990938: Bar (Snap-in type) MB991203: Oil Seal and Bearing Installer

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.

Using special tool torque tube bearing installer (MB990941), press the oil seal into the valve housing.

1.Apply specified sealant to the threaded part of the end plug. Specified sealant: 3M ATD Part No. 8663 or equivalent 2.Secure the threaded portion of the end plug at two places by using a punch.

3.Use special tool torque wrench socket (MB992351) to tighten the rack support cover. 4.Use the special tools to hold the rack support cover, and then tighten the lock nut. Tightening torque: 59 ± 10 N·m

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 preload socket (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: 0.6 - 2.0 N·m (Torque fluctuation: 0.4 N·m or less) 2. caution When adjusting, set at the highest value of the standard value range. note If the total pinion torque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary. 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.

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 variable spanner (MB992249) to install the tie rod. Tightening torque: 88 ± 10 N·m

1. caution Hold the rack housing, and use special tool bellows band crimping tool (MB992908) to crimp the bellows band securely. Crimp the bellows band until special tool (MB992908) touches the stopper. Use special tool (MB992908) to crimp the bellows band.

2.Check that crimped width (A) is within the standard value. Standard value (A): 2.4 - 2.8 mm