Mitsubishi Montero (1998+). Manual - part 290

         HYDRAULIC SYSTEM PRESSURE TEST

         1) Disconnect pressure hose from power steering pump. Attach

Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-

01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).

         2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under

LUBRICATION. Turn wheel several times to bleed air from gauge. Start

engine and let idle. Place thermometer in reservoir. Check fluid

level. Add fluid as necessary.

         3) When fluid temperature reaches 122-140



F (50-60



C), check

pressure. See POWER STEERING PUMP PRESSURE SPECIFICATIONS  table.

Reinstall pressure hose. Do not twist hose or let hose interfere with

adjacent parts. Replace power steering pump if pressure is not within

specification. Bleed system.

CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a

         time. DO NOT keep steering wheel turned to full lock

         position for more than 10 seconds at a time.

POWER STEERING PUMP PRESSURE SPECIFICATIONS

Application                                               psi (kg/cm



)

Valve Closed Or Wheel At Full Lock  ...............  1204-1305 (83-90)

Valve Open (Standard)  ...............................  114-142 (8-10)

Fig. 2:  Connecting Pressure Gauge & Shutoff Valve

Courtesy of Mitsubishi Motor Sales of America.

         P/S PRESSURE SWITCH

         1) Disconnect pressure hose from power steering pump. Attach

Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-

01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).

         2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under

LUBRICATION. Turn wheel several times to bleed air from gauge. Start

engine and let idle. Place thermometer in reservoir. Check fluid

level. Add fluid as necessary.

         3) When fluid temperature reaches 122-140



F (50-60



C),

disconnect connector from P/S pressure switch. Connect ohmmeter across

switch terminals. Slowly close shut-off valve. Check pressure when

ohmmeter indicates switch has closed (continuity). Pressure should be

218-290 (15-20 N.m). Slowly open shut-off valve. Check pressure when

ohmmeter indicates switch has opened (no continuity). Pressure should

be 102-174 (7-12 N.m). Reinstall pressure hose. Do not twist hose or

let hose interfere with adjacent parts. Replace P/S pressure switch if

pressure is not within specification. Bleed system.

CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a

         time. DO NOT keep steering wheel turned to full lock

         position for more than 10 seconds at a time.

         STEERING WHEEL TURNING FORCE

         Stationary Test

         1) Position vehicle on level surface. Place steering wheel in

straight-ahead position. Start engine and let idle. Using a spring

scale, measure steering wheel turning force clockwise and

counterclockwise.

         2) On Montero, turning force should be 8.2 lbs. (3.7 kg) or

less. On Montero Sport, turning force should be 8.8 lbs. (3.9 kg) or

less. If turning force exceeds specification, check for loose or

damaged belt, insufficient fluid, air in power steering fluid, and

collapsed or twisted hoses. Repair or replace as necessary.

         REMOVAL & INSTALLATION

         IDLER ARM

         Removal

         Loosen relay rod-to-idler arm lock nut. Using Steering

Linkage Puller (MB991113 or MB990635), separate idler arm from relay

rod and remove relay rod-to-idler arm lock nut. Remove idler arm bolts

and nuts. Remove idler arm. On Montero, loosen, but DO NOT remove

idler arm-to-bracket nut. Press arm from bracket and remove nut and

arm.

         Inspection

         Check idler arm bushings for damage or wear. Check idler arm

ball stud for looseness.

         Installation

         1) Apply multipurpose grease to inside surface of bushing and

idler arm support shaft. Insert bushing in idler arm. Insert idler arm

support in idler arm.

         2) Install washer (knurled side toward bushing) and NEW lock

nut. Tighten lock nut to specification. See  TORQUE SPECIFICATIONS.

Place idler arm assembly in vise. Using a spring gauge, measure

turning resistance.

         3) On all models, turning resistance should be 3-18 INCH lbs.

(.3-2.0 N.m). On Montero, if turning resistance is not within

specification, loosen or tighten lock nut to obtain proper resistance.

         4) Install idler arm bolts and nuts. Install relay rod-to-

idler arm. See TORQUE SPECIFICATIONS.

         POWER STEERING GEAR

         Removal & Installation

         1) Drain power steering fluid. See FLUID REPLACEMENT under

LUBRICATION. Remove steering shaft-to-steering gear clamp bolt.

Disconnect pressure and return hoses from steering gear.

         2) Remove cotter pin and castle nut from pitman arm. Using

Puller (C-3894-A), separate pitman arm from relay rod.

         3) Remove steering gear mounting nuts. Disconnect steering

shaft from steering gear. Remove steering gear. To install, reverse

removal procedure.

         POWER STEERING PUMP & RESERVOIR

         Removal

         Drain power steering fluid. See FLUID REPLACEMENT under

LUBRICATION. Disconnect hoses from reservoir. Remove reservoir.

Disconnect hoses from pump. Loosen pump retaining bolts. Remove belt.

Remove pump and mounting bracket(s).

         Installation

         To install, reverse removal procedure. Check power steering

pump bracket for slack. Tighten bracket (if necessary). Fill and bleed

reservoir. See FLUID REPLACEMENT and HYDRAULIC SYSTEM BLEEDING under

LUBRICATION. Start engine and turn steering wheel lock-to-lock to

check for fluid leaks.

         RELAY ROD

         Removal

         Remove inner tie rod end cotter pins and lock nuts. Separate

tie rod ends from relay rod. Remove cotter pins and castle nuts from

idler arm and pitman arm. Using a puller, separate relay rod from

idler arm and pitman arm.

         Installation

         To install relay rod, reverse removal procedure. Ensure dust

covers are well greased and lower edge of covers are coated with

packing sealer. Tighten relay rod-to-idler arm and relay rod-to-pitman

arm castle nuts to specification. See TORQUE SPECIFICATIONS.

         TIE ROD ASSEMBLY

         Removal

         1) Remove skid plate (if necessary). Remove cotter pins and

loosen lock nuts from tie rod ball studs at steering knuckle and relay

rod end.

         2) Using Steering Linkage Puller (MB991113 or MB990635),

separate tie rod ends from knuckle and relay rod end and remove lock

nuts. Loosen tie rod adjusting sleeve lock nuts, and unscrew tie rod

ends.

         Inspection

         Check tie rod ends for damage and ball studs for looseness.

On Montero, measure ball stud starting torque. Torque should be 9-27

INCH lbs. (1.0-3.0 N.m). If ball stud starting torque exceeds

specification, replace tie rod.

         Installation

         1) Install "O" ring on ball socket. Grease inside of tie rod

end dust cover. Coat lower edge of cup with packing sealer. Install

tie rod ends into adjusting sleeves.

         2) Measure center-to-center distance between tie rod studs

for both tie rod assemblies. Adjust center-to-center distance to

specification. See TIE ROD INSTALLATION LENGTH table.

         3) An equal number of threads should be visible on each side

of adjusting sleeve. Install tie rod ends in steering knuckle and

relay rod. Install tie rod end castle nuts and NEW cotter pins.

Tighten castle nuts to specification. See TORQUE SPECIFICATIONS.

Adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article

in WHEEL ALIGNMENT section.

TIE ROD INSTALLATION LENGTH

Application                                                   In. (mm)

Montero  ..............................................  12.05 (306.0)

Montero Sport  ...........................................  12.0 (305)

         OVERHAUL

         POWER STEERING GEAR

         Disassembly

         1) Scribe mating marks on pitman arm and cross shaft. Remove

pitman arm nut. Using a puller, remove pitman arm. Drain power

steering fluid. Remove side cover bolts. See  Fig. 3. Loosen adjusting

bolt lock nut, and screw in adjusting bolt so side cover raises

slightly.

         2) With mainshaft and cross shaft placed in straight-ahead

position, tap bottom of cross shaft with plastic hammer. Remove cross

shaft and side cover as an assembly. Remove side cover from cross

shaft by turning adjusting bolt.

         3) Remove valve housing and rack piston as an assembly by

turning rack piston counterclockwise. See Fig. 3. Carefully remove

rack piston from mainshaft without losing balls inside rack piston.

         4) Remove cross shaft oil seal from gearbox housing. Put rack

piston in soft jawed vise. Using Spanner Wrench (MB991367) and Pin Set

(MB991394), remove lock nut. Remove mainshaft while applying pressure

to bearing race to prevent balls from falling out. Drive out bearing

and oil seal.

NOTE:    DO NOT remove cross shaft "U" packing at rear of needle

         bearing unless fluid leakage is found coming from adjusting

         bolt threads. If leakage exists, replace "U" packing.