2006 MITSUBISHI LANCER Workshop Manual

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-31
•Bar (long type) (MB991197)
•Oil seal installer (MB991199)
•Oil seal and bearing installer (MB991202)

>>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 alumin-
ium, and may become deformed if press-fit on an
angle.
ACX01153
Needle bearing
MB990938
MB991202 MB991202
Lower
bearing
AE
MB990938
2. Press fit needle bearing/lower bearing with the
following special tools.
•Bar (snap-in type) (MB990938)
•Oil seal and bearing installer (MB991202)
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not close the vent hole in the rack with
grease.
ACX01154 AB
Seal ring and O-ring Vent hole
1. Apply a coating of repair kit grease to the rack
teeth face.
ACX01155
MB991212
MB991213
AJ
Oil seal
2. Cover rack serrations with the following special tool.
•Oil seal protector (MB991212)
•Oil seal protector (MB991213)
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.
>>D<< OIL SEAL/RACK BUSHING
INSTALLATION
ACX01156 AE
Oil seal
O-ring
MB990927
Rack
bushing
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.
AC100261 AC
Rack
Plastic tape
Rack bushing
2. Apply ATF DEXRON III or DEXRON II to the oil seal inner surface and the O-ring.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-32
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.
ACX01158
Circlip
Slot
AB
Circlip
Slot
Insert the circlip to the rack stopper hole through cyl-
inder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
>>F<< UPPER OIL SEAL/UPPER
BEARING INSTALLATION
ACX01159AC
MB990938
MB991203
Oil seal
MB991203 Bearing
MB990938
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.
•Bar (snap-in type) (MB990938)
•Oil seal and bearing Installer (MB991203)
>>G<< SEAL RINGS INSTALLATION
ACX01160
AB
MB991317
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.
>>H<< LOWER OIL SEAL INSTALLATION
ACX01161
Housing
AC
Oil
seal
Approximately
1 mm
MB990941
CAUTION
To eliminate a seal malfunction at the valve hous-
ing 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 hous
-
ing.
>>I<< END PLUG INSTALLATION
ACX01162
AB
End plug End plug
1. Apply specified sealant to the threaded part of the
end plug.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-33
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.
>>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 or equivalent
AC100273
MB990607
MB991621
AJ
3.Use the fo llo wing special to ol to tigh ten the rack
suppor t cover to 2 3
± 2 N⋅m.
•To rque wren ch socket (MB990607 )
•Piston driver (MB9916 21:
4.T u rn the rack suppo rt cover 30° anticlockwise .
5.Use the special tool to hold the r a ck sup port
cove r , and t hen tighten the lock nut to 59
± 10
N
⋅m.
>>K<< T O T A L PINION T O RQUE
ADJUSTMENT
CAUTION
•Be sure there is no ratcheting or catching
when operating the rack towards the shaft.
•
AC100274 AB
MB991006
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
[Change in torque: 0.6 N
⋅m or less]
Total pinion torque: 0.7 − 2.1 N⋅m
[Change in torque: 0.6 N
⋅m 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 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
ACX01163 AB
After installing the tie rod to the rack, fold tab washer
end (two locations) to tie rod notch.
>>M<< BELLOWS BAND INSTALLATION
ACX01164 AB
W MB991561
Adjusting bolt Stopper
1. Turn the adjusting bolt of special tool boot band
crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-34
NOTE: The dimension (W) is adjusted by approxi-
mately 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.
•
ACX01165AB
MB991561
Crimp the bellows band until special tool
touches the stopper.
2. Use special tool boot band crimping tool (MB991561) to crimp the bellows band.
ACX01166 AB
A
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 calcu
-
lated 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 bel-
lows band, readjust the dimension (W) of
step (1) to the value calculated by the follow
-
ing 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.]
>>N<< TIE ROD END/LOCK NUT
INSTALLATION
AC001011 AM
Lock nut
Edge of bellows
assembly groove
180 mm
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
AC100275 AB
220 mm
Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.