1999 MITSUBISHI LANCER EVOLUTION VI steering

STEERING – Power Steering Gear Box37A-9
Lubrication and Sealing Points
Fluid:
Automatic
transmission
fluid DEXRON
or DEXRON II
Grease: Repair kit grease
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Grease: Repair kit grease
Sealant:
3M ATD Part No. 8661 or
equivalent
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Grease: Silicone grease
Fluid:
Automatic transmission fluid
DEXRON or DEXRON II

STEERING – Power Steering Gear Box37A-10
DISASSEMBLY SERVICE POINTS
ARACK SUPPORT COVER REMOVAL
Use the special tool to remove the rack support cover from
the gear box.
BOIL SEAL / PINION AND VALVE ASSEMBLY
REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
CSEAL RING REMOVAL
Cut the seal ring and remove it from the pinion and valve
assembly and the rack.
Caution
When cutting the seal ring, be careful not to damage
the pinion and valve assembly or the rack.
DBALL BEARING / OIL SEAL REMOVAL
Use a socket, remove the oil seal and the ball bearing from
the valve housing assembly simultaneously.
ECIRCLIP REMOVAL
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 anticlockwise to remove the circlip.
Caution
Note that if the rack stopper is first turned
anticlockwise, the circlip will get caught in the slot
in the housing and the rack stopper will not turn.
MB990607
Socket
Rack stopper
Rack
Circlip

STEERING – Power Steering Gear Box37A-11
FRACK STOPPER / RACK BUSHING / RACK
REMOVAL
Pull out the rack assembly gently, and remove the rack stopper
and rack bushing together.
GOIL SEAL REMOVAL
Partially bend the oil seal to remove from the rack bushing.
Caution
Do not damage the oil seal press fitting surface of the
rack bushing.
HBALL BEARING REMOVAL
Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
INEEDLE ROLLER BEARING REMOVAL
Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open the special tool excessively to prevent
damaging housing interior.
JOIL SEAL REMOVAL
Use a piece of pipe or similar tool to remove the oil seal
from the gear housing.
Caution
Be careful not to damage the inner surface of the rack
cylinder of the gear housing.
Rack bushing
Ball
bearing MB990939 or
brass bar
MB991120
Needle roller
bearing
Gear housing
Pipe or similar tool
Oil seal

STEERING – Power Steering Gear Box37A-12
REASSEMBLY SERVICE POINTS
AGEAR HOUSING MOUNTING RUBBER
INSTALLATION
1. Install the gear housing mounting rubber on the rack
housing so that the dimension shown is achieved.
NOTE
The gear housing mounting rubber can be installed
regardless of the installation direction of the slit.
2. Apply specified adhesive to the slit of the gear housing
mounting rubber.
Specified adhesive:
3M ATD Part No. 8155 or equivalent
BOIL SEAL INSTALLATION
CNEEDLE ROLLER BEARING / BALL BEARING
INSTALLATION
DRACK INSTALLATION
1. Apply a coating of repair kit grease to the rack tooth
face.
Caution
Do not close the vent hole in the rack with grease.
Slit Gear housing
mounting rubber3.1 mm
MB991452
Oil sealMB991197
(Bar)
Needle roller
bearing
MB990938
MB991202MB990938
MB991202
Ball bearing
Vent hole

STEERING – Power Steering Gear Box37A-13
2. Cover rack serrations with special tool.
3. Apply the specified fluid on the special tool.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
4. Match the oil seal centre with rack to prevent retainer
spring from slipping and slowly insert rack from power
cylinder side.
EOIL SEAL / RACK BUSHING INSTALLATION
1. Apply the specified fluid to the outer surface of the oil
seal. Press-fit the oil seal using the special tool until it
is flush with the bushing end face.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
FCIRCLIP INSTALLATION
Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
GOIL SEAL / BALL BEARING INSTALLATION
1. Apply a coating of the specified fluid to the outside of
the oil seal. Using the special tools, press the oil seal
into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
MB991214
Oil seal
Oil seal
MB990927
Rack
bushingO-ring
Rack bushingPlastic tape
Circlip
SlotCirclip
Slot
Oil sealMB990938
MB991203

STEERING – Power Steering Gear Box37A-14
2. Apply a coating of the specified fluid to the outside of
the ball bearing. Using the special tools, press the ball
bearing into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
HSEAL RING INSTALLATION
1. Kneed the seal ring to soften it.
2. Apply the specified fluid to the seal ring, and install to
the rack groove.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
IOIL SEAL INSTALLATION
Use the special tool to press the oil seal into the valve housing.
The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
JEND PLUG INSTALLATION
1. Apply the specified sealant to the threaded part of the
end plug.
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.
KTOTAL PINION TORQUE ADJUSTMENT
1. Position the rack at its centre. Tighten the rack support
cover to 15 Nm.
2. In neutral position, rotate the pinion shaft clockwise one
turn/4 – 6 seconds with the special tool. Return the rack
support cover 30 – 60 and adjust torque to the standard
value.
Ball bearingMB990938
MB991203
Pinion gearMB991317
Tapered side
Approx. 1 mmMB990941
End plug
SealantEnd plug
MB991006

STEERING – Power Steering Gear Box37A-15
3. Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
(1) When adjusting, set the standard value at its
highest value.
(2) Assure no ratcheting or catching when operating
the rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check or replace the rack support cover
components.
4. After adjusting, lock the rack support cover with lock nut.
LTAB WASHER / TIE-ROD INSTALLATION
After installing the tie-rod to the rack, fold the tab washer
end (2 locations) to the tie-rod notch.
MBELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
Standard value (W): 2.9 mm

Screw in the adjusting bolt.

Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by approx. 0.7 mm
per one turn.
(2) Do not turn the adjusting bolt more than one turn.
MB991006
MB991561
Stopper
Adjusting bolt W

STEERING – Power Steering Gear Box37A-16
2. Use the special tool to crimp the bellows band.
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.
3. Check that the crimped width (A) is within the standard
value.
Standard value (A): 2.4 – 2.8 mm

Readjust the dimension (W) of step (1) to the value
calculated 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.]

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 – A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
NTIE-ROD END / TIE-ROD END LOCKING NUT
INSTALLATION
Screw in the tie-rod end until the dimension shown is achieved.
Then, temporarily tighten with the locking 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
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease inside a new dust cover.
2. Using the special tool, press in the dust cover to the
tie rod end.
3. Check the dust cover for cracks or damage by pushing
it with finger.
MB991561
A
212 mm Edge of bellows
assembly grooveLock nut
MB990776