Mitsubishi L200. Manual - part 482

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-31

<<E>> SEAL RING REMOVAL

CAUTION

When cutting the seal ring, be careful not to dam-
age the pinion and valve assembly or the rack.

ACX01144 AB

Cut the seal ring and remove it from the pinion and 
valve assembly or the rack.

<<F>> UPPER BEARING/UPPER OIL SEAL 
REMOVAL

ACX01145AC

Socket

Using a socket, remove the oil seal and the ball bear-
ing from the valve housing simultaneously.

<<G>> CIRCLIP REMOVAL

CAUTION

If the rack stopper is first turned anticlockwise, 
the circlip will get caught in the slot in the hous-
ing and the rack stopper will not turn.

ACX01146 AB

Circlip

Rack stopper

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.

<<H>> RACK STOPPER/RACK BUSHING 
ASSEMBLY/O-RING/OIL SEAL/RACK ASSEMBLY 
REMOVAL

ACX01147 AB

1. Pull out the rack slowly. Take out the rack stopper 

and the rack bushing at the same time.

CAUTION

Do not damage the oil seal press fitting surface.

ACX01148 AB

Rack bushing

2. Partially bend the oil seal and remove it from the 

rack bushing.

<<I>> LOWER BEARING REMOVAL

ACX01149

MB990939

Lower bearing

AC

Valve housing

Use a brass bar or special tool brass bar 
(MB990939) to remove the ball bearing from the gear 
housing.

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-32

<<J>> NEEDLE BEARING REMOVAL

CAUTION

Do not open special tool needle bearing puller 
(MB991120) excessively to prevent damaging 
housing interior.

ACX01150 AB

Valve housing

MB991120

Needle 
bearing

Use special tool needle bearing puller (MB991120) to 
remove the needle bearing from the rack housing.

<<K>> OIL SEAL REMOVAL

CAUTION

Be careful not to damage the inner surface of the 
rack cylinder of the gear housing.

AC100259

Oil seal

Pipe or similar tool

Gear housing

AB

Use a piece of pipe or similar tool to remove the oil 
seal from the gear housing.

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

AC802691

AD

Piston

Rack assembly

Oil seal

Plastic tape

1. Wrap the rack assembly teeth face with plastic 

tape, and apply a coating of ATF DEXRON III or 
DEXRON II.

2. Insert the oil seal in rack assembly, and move to 

the piston.

>>B<< NEEDLE BEARING/LOWER BEARING 
INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing, 

bearing and oil seal 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

AH

MB990938

2. Press fit needle bearing with following special 

tools.

• Bar (snap-in type) (MB990938)

• Oil seal and bearing installer (MB991202)

>>C<< RACK ASSEMBLY INSTALLATION

CAUTION

Do not plug the vent hole in the rack with grease.

AC802691

AE

Seal ring and o-ring

Vent hole

Oil seal

1. Removal the plastic tape, and apply a coating of 

multipurpose grease to the rack teeth face.

2. Apply a coating of ATF DEXRON III or DEXRON II 

to the outer surface of the seal ring and the O-
ring.

3. Slowly insert the rack from power cylinder side.

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-33

>>D<< OIL SEAL/O-RING/RACK BUSHING 
ASSEMBLY 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 the special tool 
installer adapter (MB990927), press in the oil seal 
until it is flush with the bushing end face.

AC500042 AC

Rack bushing

Vinyl tape

Rack

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.

ACX01158

Circlip

Slot

AD

Circlip

Slot

Rack stopper

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 
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 RING 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

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.

ACX01161

Housing

AC

Oil
seal

Approximately
1 mm

MB990941

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-34

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.

Specified sealant:
3M ATD Part No. 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. 8663 or equivalent

AC100273 AO

MB991621
MB992351

<2WD (Except High rider)>

<2WD (High rider), 4WD>

3. Use special tool rack support cover wrench 

(MB991621) <2WD (except High rider)>, torque 
wrench socket (MB992351) <2WD (High rider), 
4WD> to tighten the rack support cover.

4. Use the special tools 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.

•

AC100274AB

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

Standard value:
Total pinion torque: 0.6 

− 1.7 N⋅m 

[Torque fluctuation: 0.4 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<< TIE ROD INSTALLATION

CAUTION

Do not tighten the vise strongly in order not to 
damage the rack bar.

AC700957AD

Tie rod

Steering gear

Rack bar

Cloth

1. Wrap rack bar with cloth in order not to damage, 

and fix the rack bar with a vise.