Mitsubishi Outlander (2003+). Manual - part 292

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-27

>>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.

œ

MB990938: Bar (Snap-in type)

œ

MB991203: Oil Seal and Bearing Installer

>>G<< SEAL RING 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.

>>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/JAM 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 equivalent

ACX01159AC

MB990938

MB991203

Oil seal

MB991203

Bearing

MB990938

ACX01160 AB

MB991317

ACX01161

Housing

AC

Oil
seal

Approximately
1 mm

MB990941

ACX01162 AB

End plug

End plug

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3. Use special tool rack support cover wrench 

(MB991621) to tighten the rack support cover to 
23 

–

 2 N

¼

m.

4. Turn the rack support cover 30

•

 counterclockwise.

5. Use the special tool to hold the rack support 

cover, and then tighten the jam nut to 59 

–

 10 

N

¼

m.

>>K<< TOTAL PINION TORQUE ADJUSTMENT

CAUTION

œ

Be sure there is no ratcheting or catching 
when operating the rack towards the shaft.

œ

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 
four to six seconds to check the total pinion torque 
and the change in torque.

Standard value:
Total pinion torque: 0.7 

-

 1.6 N

¼

m

[Change in torque: 0.4 N

¼

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

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
<When more than 2.9 mm>: Screw in the 
adjusting bolt.
<When less than 2.9 mm>: Loosen the 
adjusting bolt.

AC100273

MB991621

AC

AC100274 AB

MB991006

ACX01163 AB

ACX01164 AB

W

MB991561

Adjusting bolt

Stopper

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CAUTION

œ

Hold the rack housing, and use special tool to 
crimp the bellows band securely.

œ

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

<When more than 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.]
<When less than 2.4 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.]

>>N<< TIE ROD END/JAM NUT INSTALLATION

Screw in the tie rod end to achieve the right and left 
length as illustrated. Lock with the jam nut.

NOTE: The jam 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.

ACX01165 AB

MB991561

ACX01166 AB

A

AC001011 AH

Jam nut

Edge of bellows
assembly groove

186 mm

AC100275AB

220 mm

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TIE ROD END BALL JOINT DUST COVER 
REPLACEMENT

M1372008200305

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.

AC001012AB

MB990776