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Mitsubishi Montero (1991+). Manual - part 203

piston rod movement. If dents don’t restrict movement, no

service is suggested or required. Especially critical on

mono-tube dampers.

(2) - This condition can lead to damage of the piston rod,

which, in turn, causes premature piston rod seal wear.

(3) - If noise is isolated to damper, suggest replacement.

STEERING GEARS (EXCEPT RACK AND PINION)

If diagnosis has determined that complete disassembly is

necessary to determine the extent of the system failure, the

suggestion may be made to rebuild or replace the power steering pump.

Repair or replacement of the following components may be required, if

performed as part of a power steering pump overhaul or rebuild service

to meet a minimum rebuild standard.

STEERING GEAR (EXCEPT RACK AND PINION) INSPECTION

Condition Code Procedure

Attaching hardware

broken ................. A .. Require replacement of broken

part.

Attaching hardware

loose .................. A .. Require repair or replacement

of loose part.

Attaching hardware

missing ................ C ......... Require replacement of

missing part.

Attaching hardware

threads damaged ........ A .. Require repair or replacement

of part with damaged threads.

Attaching hardware

threads stripped

(threads missing) ...... A .... Require replacement of part

with stripped threads.

Binding ................. A ... Require repair or replacement

Flex coupler binding .... A ... Require repair or replacement

of coupler.

Flex coupler loose ...... A ... Require repair or replacement

of coupler.

Flex coupler

missing parts .......... A ... Require repair or replacement

of coupler.

Flex coupler

soft/spongy ............ A . Require replacement of coupler.

Flex coupler torn ....... A . Require replacement of coupler.

Fluid contaminated ...... B ........ (1) Require flushing and

refilling of the system.

Gasket leaking .......... A ... Require repair or replacement

of gasket.

Housing leaking ......... A ............ Require replacement.

Hydraulic fittings

leaking ................ A ... Require repair or replacement

of fittings.

Inadequate power assist . A .......... ( 2) Further inspection

required.

See note below.

Lash exceeds

manufacturer’s

specifications .......... B .. Require repair or replacement.

Seal leaking ............ A ... Require repair or replacement

of seal and/or mating part.

Splines damaged ......... A ... Require repair or replacement

of splines.

Splines stripped ........ A . Require replacement of splines.

Steering coupler

shield cracked ......... 2 ............ Suggest replacement.

Steering coupler

shield missing ......... C ............ Require replacement.

Threads damaged ......... A ... Require repair or replacement

of part with damaged threads.

Threads stripped

(threads missing) ...... A ..... Require replacement of part

with stripped threads.

U-joint binding ......... A ... Require repair or replacement

of joint.

U-joint loose ........... A ... Require repair or replacement

of joint.

Unequal power assist .... A .. Require repair or replacement.

(1) - Determine and correct source of contamination. OEM

specifications must be followed for fluid type.

(2) - If steering gear is source of inadequate assist, require

repair or replacement.

STEERING GEARS - RACK AND PINION

If diagnosis has determined that complete disassembly is

necessary to determine the extent of the system failure, the

suggestion may be made to rebuild or replace the power steering pump.

Repair or replacement of the following components may be required, if

performed as part of a power steering pump overhaul or rebuild service

to meet a minimum rebuild standard.

STEERING GEARS - RACK AND PINION INSPECTION

Condition Code Procedure

Attaching hardware

broken ................. A ......... Require replacement of

broken part.

Attaching hardware

loose .................. A .. Require repair or replacement

of loose part.

Attaching hardware

missing ................ C ......... Require replacement of

missing part.

Attaching hardware

threads damaged ........ A .. Require repair or replacement

of part with damaged threads.

Attaching hardware

threads stripped

(threads missing) ...... A .... Require replacement of part

with stripped threads.

Balance tube blocked .... A .. Require repair or replacement

of balance tube.

Balance tube missing .... C .. Require replacement of balance

tube.

Balance tube restricted . A ... Require repair or replacement

of balance tube.

Bellows boot

clamp missing .......... C ... Require replacement of clamp.

Bellows boot cracked

(not through) .......... 2 .. Suggest replacement of bellows

boot.

Bellows boot missing .... C .. Require replacement of bellows

boot.

Bellows boot

not sealing ............ A ... Require repair or replacement

of bellows boot.

Bellows boot torn ....... A .. Require replacement of bellows

boot.

Bellows boot twisted

(from toe adjustment) .. B ................. Require repair.

Fitting leaking ......... A .. Require repair or replacement.

Fitting missing ......... A . Require replacement of fitting.

Fitting threads

damaged ................ A ... Require repair or replacement

of part with damaged threads.

Fitting threads stripped

(threads missing) ...... A ..... Require replacement of part

with stripped threads.

Flex coupler binding .... A ... Require repair or replacement

of coupler.

Flex coupler loose ...... A ... Require repair or replacement

of coupler.

Flex coupler

missing parts .......... A ... Require repair or replacement

of coupler.

Flex coupler

soft/spongy ............ A . Require replacement of coupler.

Flex coupler torn ....... A . Require replacement of coupler.

Fluid contaminated ...... B ........ (1) Require flushing and

refilling of the system.

Gasket leaking .......... A .. Require repair or replacement.

Hard steering on cold

start-up ............... 1 ........... ( 2) Suggest repair or

replacement.

Housing cracked,

affecting structural

integrity .............. B ............ Require replacement.

Housing leaking ......... A ............ Require replacement.

Inadequate power assist . A .......... ( 3) Further inspection

required.

Lash exceeds

manufacturer’s

specifications ......... B .. Require repair or replacement.

Seal leaking ............ A .. Require repair or replacement.

Splines damaged ......... A .. Require repair or replacement.

Splines stripped

(splines missing) ...... A ............ Require replacement.

Steel line blocked ...... A ... Require repair or replacement

of line.

Steel line leaking ...... A ... Require repair or replacement

of line.

Steel line missing ...... C .... Require replacement of line.

Steel line restricted ... A ... Require repair or replacement

of line.

Steering coupler shield

cracked ................ 2 ............ Suggest replacement.

Steering coupler shield

missing ................ C ............ Require replacement.

Steering coupler shield

torn ................... 2 ............ Suggest replacement.

Threads damaged ......... A ... Require repair or replacement

of part with damaged threads.

Threads stripped

(threads missing) ...... A ..... Require replacement of part

with stripped threads.

U-joint binding ......... A ... Require repair or replacement

of joint.

U-joint loose ........... A ... Require repair or replacement

of joint.

Unequal power assist .... A .. Require repair or replacement.

(1) - Determine and correct source of contamination. Follow OE

specifications for fluid type.

(2) - Indicates internal wear.

(3) - If steering gear is source of inadequate assist, require

repair or replacement.

STEERING KNUCKLES

STEERING KNUCKLE INSPECTION

Condition Code Procedure

Attaching hardware

bent ................... B ... Require repair or replacement

of bent part.

Attaching hardware

broken ................. A ... Require replacement of broken

part.

Attaching hardware

incorrect .............. A .......... Require replacement of

incorrect part.

Attaching hardware

loose .................. A ... Require repair or replacement

of loose part.

Attaching hardware

missing ................ C .. Require replacement of missing

part.

Attaching hardware

threads damaged ........ A ... Require repair or replacement

of part with damaged threads.

Attaching hardware

threads stripped

(threads missing) ...... A ..... Require replacement of part

with stripped threads.

Bent .................... B ............ Require replacement.

Broken .................. A ............ Require replacement.

Pinch bolt incorrect .... B ... Require replacement with bolt

that meets OE design.

Pinch bolt loose ........ B ................. Require repair.

Pinch bolt missing ...... B ............ Require replacement.

Pinch bolt tabs

deformed (pinched

together), .032"

or more before

clamping ............... B ........ (1) Require replacement.

Taper hole elongated .... A ........ (2) Require replacement.

Threads damaged ......... A .. Require repair or replacement.

Threads stripped (threads

missing) ............... A .. Require repair or replacement.

(1) - Steering knuckle deformation can cause pinch

bolt breakage.

(2) - Check for damaged stud.

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