Mitsubishi Lancer. Manual - part 196

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-32

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 STEERING

37-33

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 <Invite>
MB991621 <Intense>

AJ

3. Use the following special tool to tighten the rack 

support cover to 23 

± 2 N⋅ m.

• Torque wrench socket (MB990607) <Invite>

• Piston driver (MB991621: <Intense>

4. Turn the rack support cover 30

°  anticlockwise.

5. Use the special tool 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 
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 <Invite> 

[Change in torque: 0.6 N

⋅ m or less]

Total pinion torque: 0.7 

− 2.1 N⋅ m <Intense> 

[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 STEERING

37-34

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

CAUTION

• Hold the rack housing, and use special tool to 

crimp the bellows band securely.

•

ACX01165 AB

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

<When more than 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.]
<When less than 2.4 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

AC001011AM

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

AC100275AB

220 mm

Install the gear mounting rubber to the rack housing 
so that the distance is as shown in the illustration.

POWER STEERING OIL PUMP ASSEMBLY

POWER STEERING

37-35

TIE ROD END BALL JOINT DUST COVER 
REPLACEMENT

M1372008200327

If the dust cover is damaged accidentally during 
service work, replace the dust cover as follows:

AC001012AB

MB990776

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.

POWER STEERING OIL PUMP ASSEMBLY

REMOVAL AND INSTALLATION

M1372005200298

Pre-removal Operation
• Power Steering Fluid Draining (Refer to 

P.37-13

).

Post-installation Operation
• Power Steering Fluid Supplying and Bleeding (Refer to 

P.37-14

).

• Drive Belt Tension Check (1300, 1600: refer to GROUP 

11A, On-vehicle Service 

− Drive Belt Tension Check 

P.11A-7

/2000: refer to GROUP 11C, On-vehicle Service 

− 

Drive Belt Tension Check 

P.11C-7

).

<1300, 1600>

AC209708

8

7

1

2

3

4

5

6

57 ± 7 N·m

40 ± 4 N·m

22 ± 4 N·m

N

9

40 ± 5 N·m

AC