Mitsubishi Lancer Evolution IX. Manual - part 325

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-25

DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER 
REMOVAL

AC103692 AF

MB991621

Using the following special tool piston driver 
(MB991621), remove the rack support cover from the 
steering gear.

<<B>> LOWER OIL SEAL/PINION AND 
VALVE ASSEMBLY REMOVAL

ACX01143 AB

Using a plastic hammer, gently tap the pinion to 
remove it.

<<C>> 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.

<<D>> 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.

<<E>> 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.

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

ACX01147 AB

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-26

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.

<<G>> LOWER BEARING REMOVAL

ACX01149

MB990939

Lower bearing

AC

Valve housing

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

<<H>> NEEDLE BEARING REMOVAL

CAUTION

Do not open special tool 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 valve housing.

<<I>> 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

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

to the both sides of the oil seal.

AC100260 AF

MB991197

Oil seal

MB991199 

Gear housing

2. Using the following special tools, press the oil seal 

into the rack housing.

• Bar (long type) (MB991197)

• Oil seal installer (MB991199)

>>B<< NEEDLE BEARING/LOWER 
BEARING INSTALLATION

1. Apply ATF DEXRON III or DEXRON II to housing 

and bearing press fitting surface.

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-27

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

MB991214

AH

Oil seal

2. Cover rack serrations with the following special 

tool oil seal protector (MB991214).

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.

AC100261AC

Rack

Plastic tape

Rack bushing

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

AB

Circlip

Slot

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-28

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.

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