2005 MITSUBISHI LANCER Workshop Manual

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-32
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
2. Using the following special tools, press the oil seal
into the rack housing.
•MB991197: Bar (long type)
•MB991199: Oil Seal Installer
•MB991202: Oil Seal and Bearing Installer

>>B<< NEEDLE BEARING/LOWER
BEARING INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing
and bearing press fitting surface.
CAUTION
Press-fit straight. The valve housing is
aluminium, and may become deformed if
press-fit on an angle.
2. Press fit needle bearing/lower bearing with the
following special tools.
•MB990938: Bar (snap-in type)
•MB991202: Oil Seal and Bearing Installer
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not close the vent hole in the rack with
grease.
1. Apply a coating of repair kit grease to the rack
teeth face.
2. Cover rack serrations with the following special
tool.
•MB991212: Oil Seal Protector
•MB991213: Oil Seal Protector
3. Apply ATF DEXRON III or DEXRON II to special
tool, and to the outer surface of the seal ring and
the O-ring.
4. Align the centre of the oil seal with the rack to
prevent the retainer spring from slipping. Slowly
insert the rack from power cylinder side.
AC100260AD
MB991197
Oil seal MB991202
MB991199
Gear housing
ACX01153
Needle bearing
MB990938
MB991202MB991202
Lower
bearing
AE MB990938
ACX01154
AB
Seal ring and O-ringVent hole
ACX01155
MB991212
MB991213
AG
Oil seal

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-33
>>D<< OIL SEAL/RACK BUSHING
INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to the outer
surface of the oil seal. Using special tool installer
adapter (MB990927), press in the oil seal until it is
flush with the bushing end face.
2. Apply ATF DEXRON III or 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.
>>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 ATF DEXRON III or DEXRON II to
the outside of the upper oil seal/upper bearing. Using
the 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
>>G<< SEAL RINGS INSTALLATION
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.
ACX01156AE
Oil seal
O-ring MB990927
Rack
bushing
AC100261
AC
Rack
Plastic tape
Rack bushing
ACX01158
Circlip
Slot
AB
Circlip
Slot
ACX01159AC MB990938
MB991203
Oil seal
MB991203
Bearing MB990938
ACX01160AB
MB991317

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-34
>>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 from the housing edge
surface.
Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve
housing.
>>I<< END PLUG INSTALLATION
1. Apply specified sealant to the threaded part of the
end plug.
Specified sealant: 3M ATD Part No.8661,
8663 or equivalent
2. Secure the threaded portion of the end plug at two
places by using a punch.
>>J<< RACK SUPPORT COVER/LOCK
NUT INSTALLATION
1. Position the rack at its centre.
2. Apply specified sealant to the threaded part of the
rack support cover.
Specified sealant:
3M ATD Part No.8661, 8663 or equivalent3. Use the following special tool to tighten the rack
support cover to 23 ± 2 N⋅m.
•MB990607: Torque Wrench Socket
•MB991621: Piston Driver
4. Turn the rack support cover 30° anticlockwise.
5. Use the special tool to hold the rack support
cover, and then tighten the lock nut to 59 ± 10
N⋅m.
>>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 preload socket (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 − 2.1 N⋅m <1300,
1600(Comfort)>
[Change in torque: 0.6 N⋅m or less]
Total pinion torque: 0.7 − 2.1 N⋅m <1600(Sport),
2000>
[Change in torque: 0.6 N⋅m or less]
ACX01161
Housing
AC
Oil
seal
Approximately
1 mm
MB990941
ACX01162
AB
End plugEnd plug
AC100273
MB990607
MB991621
AD
AC100274 AB
MB991006

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-35
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 specified return
angle, check the rack support cover components
and replace any parts if necessary.
2. 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.
>>L<< TAB WASHER/TIE ROD
INSTALLATION
After installing the tie rod to the rack, fold tab washer
end (two locations) to tie rod notch.
>>M<< BELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of special tool boot band
crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.
NOTE: The dimension (W) is adjusted by
approximately 0.7 mm per one turn.
NOTE: Do not turn the adjusting bolt more than
one turn.
Standard value (W): 2.9 mm: Screw in the
adjusting bolt.
: Loosen the
adjusting bolt.
CAUTION
•Hold the rack housing, and use special tool to
crimp the bellows band securely.
•Crimp the bellows band until special tool
touches the stopper.
2. Use special tool boot band crimping 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
: 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.]
ACX01163
AB
ACX01164
AB
WMB991561
Adjusting boltStopper
ACX01165AB
MB991561
ACX01166
AB
A

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-36
>>N<< TIE ROD END/LOCK NUT
INSTALLATION
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut.
NOTE: The lock nuts must be tightened securely
only after the steering gear is installed to the vehicle
and toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER
INSTALLATION
Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply specified grease to the lip and inside of the
dust cover.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
3. Check the dust cover for cracks or damage by
pushing it with your finger.
AC001011
AM
Lock nut Edge of bellows
assembly groove
180 mm
AC100275
AB
220 mm
AC001012
AB
MB990776

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-37
POWER STEERING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATIONM1372005200298
<1300, 1600>
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13).Post-installation Operation
•Power Steering Fluid Supplying and Bleeding (Refer to
P.37-13).
•Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service − Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service −
Drive Belt Tension Check P.11C-7).
AC209708
87
12 34
5
6
57 ± 7 N·m
40 ± 4 N·m 22 ± 4 N·m
N
9
40 ± 5 N·m
AC
Removal steps
1. Pressure switch connector
2. A/C compressor harness connector
bracket
3. Drive belt
4. Suction hose5. Eye bolt
6. O-ring
7. Pressure hose
8. Oil pump assembly
9. Oil pump braceRemoval steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-38
<2000>
REMOVAL SERVICE POINT
<> OIL PUMP ASSEMBLY REMOVAL
<2000>
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
INSPECTIONM1372005300187
•Check the drive belt for cracks.
•Check the pulley for uneven rotation.
AC200116
AB
22 ± 4 N·m 12 ± 2 N·m
22 ± 4 N·m 49 ± 9 N·m57 ± 7 N·m
1
5 4 3
6 2
7
49 ± 9 N·m
Removal steps
1. Pressure switch connector
2. Drive belt
3. Suction hose
4. Pressure hose<>5. Oil pump assembly
6. A/C compressor harness
7. Power steering pump bracketRemoval steps (Continued)