2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

STEERING - Power Steering Gear Box and Linkage37A-23
AF"RACK STOPPER/RACK BUSHING/OIL SEAL/
O-RING/RACK ASSEMBLY REMOVAL
1. Remove the rack stopper, rack bushing, oil seal and O-ring
together by pulling out the rack gently.
2. Partially bend the oil seal to remove from the rack bushing.
Caution
Use care not to damage the oil seal press-fitting
surface of the rack bushing.
AG"LOWER BEARING REMOVAL
AH"NEEDLE BEARING REMOVAL
Caution
Do not open the special tool to much, otherwise it may
damage the inside surface of the valve housing.
AI"OIL SEAL REMOVAL
Use a pipe or the like to pull out the oil seal.
Rack bushing
Valve
housing
MB990925
(MB990939)
Lower
bearing
MB991120
Needle
bearing Valve
housing
Oil seal
Gear housing
Pipe

STEERING - Power Steering Gear Box and Linkage37A-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
"BANEEDLE BEARING/LOWER BEARING
INSTALLATION
"CARACK ASSEMBLY INSTALLATION
1. Apply repair kit grease to the teeth of the rack assembly.
Caution
Use care not to close the vent hole in the rack with
grease.
2. Cover the serrations of the rack assembly with the special
tool.
3. Apply specified fluid to the outer surfaces of the special
tool, seal ring and O-ring.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
4. Slowly insert the rack covered with the special tool from
the power cylinder side of the gear housing.
Caution
Carefully push in the rack with the oil seal centre
and the special tool end matched. This is to avoid
the retainer spring coming off.MB991197
Gear housing
Oil seal MB991199
Needle
bearingMB990925
(MB990938)
MB991202
Lower
bearing MB990925
(MB990938)
MB991202
Vent hole
Seal ring, O-ring
MB991214 Oil seal

STEERING - Power Steering Gear Box and Linkage37A-25
"DAOIL SEAL/RACK BUSHING INSTALLATION
1. Apply specified fluid to the outer surface of the oil seal.
Using the special tool, press in the oil seal until it is flush
with the bushing end face.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
"EACIRCLIP INSTALLATION
Align the mark on the rack stopper and the slot in the cylinder.
Then, insert the circlip into the rack stopper hole through
the cylinder hole. Turn the rack stopper clockwise and insert
the circlip firmly.
"FAUPPER OIL SEAL/UPPER BEARING
INSTALLATION
"GASEAL RING INSTALLATION
After installation, using the special tool or by hand, compress
seal rings that expand during installation.
MB990925
(MB990927)
Oil seal
O-ring
Rack
bushing
Rack bushingPlastic tape Rack
Slot
Circlip
SlotCirclip
MB991203MB991203 MB990925
(MB990938)
Upper oil
seal
MB990925
(MB990938)
Bearing
MB991317

STEERING - Power Steering Gear Box and Linkage37A-26
"HALOWER OIL SEAL INSTALLATION
Using the special tool, press the oil seal into the valve housing.
The upper surface of the oil seal must project outwards about
1 mm from the housing end surface.
Caution
When the oil seal is flush with or lower than the housing
edge, reassemble the components. Otherwise, oil leaks
will result.
"IAEND PLUG INSTALLATION
1. Apply specified sealant to the threaded section of the
end plug, and then install the end plug to the gear housing.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Use a punch to bend over the two tabs on the sides
of the end plug to stop the end plug from turning.
"JARACK SUPPORT COVER/LOCKING NUT
INSTALLATION
1. Apply specified sealant to the rack support cover thread.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Using the special tool, tighten the rack support cover
to 23±2 N·m.
3. Return the rack support cover by about 30_.
4. Tighten the locking nut to the specified torque, using
the special tool to prevent the rack support cover from
spinning.
"KAPINION TOTAL ROTATION TORQUE ADJUSTMENT
1. Using the special tool, measure total rotation torque by
turning the pinion gear at a speed of one rotation per
4 to 6 seconds.
Standard value:
Total rotation torque: 0.8-1.8 Nm
Torque fluctuation: 0.49 Nm or lessMB990941 Approx. 1 mmOil
seal
Housing
End plugEnd plug
MB991204
MB991006

STEERING - Power Steering Gear Box and Linkage37A-27
2. If the total rotation torque or torque fluctuation does not
meet the standard values, adjust by returning the rack
support cover within a range of 0 to 30_.
Caution
(1) Adjust around the maximum limit of the standard
values.
(2) See that no ratcheting or catching are present
when operating the rack towards the shaft
direction.
(3) Measure the total pinion torque through the whole
stroke of the rack.
3. If the adjustment is impossible in the given range, check
the components of the rack support cover, and replace
if necessary.
"LATAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold the tab washer
end (2 locations) to the tie rod notch.
"MABELLOWS 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 about 0.7 mm per
one turn.
(2) Do not turn the adjusting bolt more than one turn.
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.
MB991561
Stopper
Adjusting bolt W
MB991561

STEERING - Power Steering Gear Box and Linkage37A-28
3. See that the crimped width (A) meets 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.]
"NATIE 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.
"OAGEAR 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
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease to the inside of the dust cover.
2. Drive in the dust cover with special tool until it is fully
seated.
3. Check the dust cover for cracks or damage by pushing
it with finger.
A
Edge of bellows
assembly grooveLocking nut
184 mm
220 mm
MB990776

STEERING - Power Steering Oil Pump37A-29
POWER STEERING OIL PUMP
REMOVAL AND INSTALLATION
Caution
After temporary tightening all bolts in * part, tighten in specific torque.
Pre-removal Operation
Power Steering Fluid Draining (Refer to P.37A-9.)Post-installation Operation
DPower Steering Fluid Supplying and Bleeding
(Refer to P.37A-9.)
DDrive Belt Tension Adjusting
(Refer to GROUP 11A – On-vehicle Service.)
22±4 N·m
8
40±5 N·m 18±3 N·m
3
45
2
5
22±4 N·m*
1 7
6
40±5 N·m* 22±4 N·m
Removal steps
1. Pressure switch connector
2. Drive belt (Refer to GROUP 11A.)
"BA3. Suction hose connection
"BA4. Pressure hose connection"AA5. O ring
6. Heat protecter
7. Oil pump assembly
8. Power steering pump bracket
INSTALLATION SERVICE POINTS
"AAO-RING INSTALLATION
No.ID×Width mm
111.0×1.9
213.0×1.9
21

STEERING - Power Steering Oil Pump/Power Steering Oil Hoses37A-30
"BAPRESSURE HOSE ASSEMBLY/SUCTION HOSE
REMOVAL
Install the pressure hose assembly and suction hose as
illustrated.
DISASSEMBLY AND REASSEMBLY
21±3 N·m
3
4
2 1
39±5 N·m
: Automatic transmission fluid DEXRONII
NOTE
Disassembly steps
1. Suction connector
2. O-ring3. Connector
4. Gasket
POWER STEERING OIL HOSES
REMOVAL AND INSTALLATION
Caution
1. Before removing the clock spring, always see GROUP 52B - Caution for Service and Air Bag
Module Clock Spring
2. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper, because the paint of caliper will be scratched.
3. On the tightening section indicated in the mark (*), lightly tighten the nut first, and then finally
tighten it with the engine weight applied on the body.
Suction hose
Pressure hose
assembly
Marking
Notch