Mitsubishi Montero (1998+). Manual - part 291

Fig. 3:  Exploded View Of Power Recirculating Ball Steering Gear

Courtesy of Mitsubishi Motor Sales of America.

         Inspection

         Check mainshaft for wear and damage. Check tooth surface of

cross shaft and rack piston for wear and damage. Check contact part of

adjusting bolt for uneven wear. Check dust seal, oil seal and "O"

rings for wear and damage.

         Reassembly

         1) Install NEW cross shaft lower "U" packing (if removed).

Press lower cross shaft oil seal into gearbox housing. See  Fig. 3.

Press bearing and oil seal into top cover. Install bearing race and

"O" ring.

         2) Apply transmission fluid to seal ring contact areas on

mainshaft, and install seal rings firmly into valve grooves. Wrap

serrated part of mainshaft with vinyl tape. Mount valve body to valve

housing. Install cage and align hole in cage with channel in

mainshaft. Install bearing race and insert balls.

         3) Install mainshaft into valve housing while pressing on

bearing race to prevent balls from falling out. Using spanner wrench,

install lock nut and tighten until it contacts bearing race.

         4) Tighten lock nut while measuring mainshaft endplay using

dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch

to crimp circumference of lock nut. Ensure mainshaft rotates freely.

         5) Apply transmission fluid to "O" ring and piston seal ring,

and install into gearbox housing. Install rack piston until it

contacts edge of mainshaft. Rotate mainshaft to align ball raceway

with insertion hole. Install 19 balls.

NOTE:    Insert balls so no clearance exists between balls.

         6) Place remaining 7 balls in circulator and install

circulator to rack piston. Install circulator holder. Install NEW

cross shaft upper "U" packing (if removed). Install upper cross shaft

"O" ring. Apply transmission fluid to rack piston seal ring and insert

valve housing. Rotate mainshaft until rack piston is centered (neutral

position).

         7) Install adjusting plate so beveled part is facing upward.

Using a feeler gauge, measure clearance between adjusting bolt and

cross shaft. If clearance is greater than .002" (.05 mm), replace with

appropriate adjusting plate.

         8) Apply multipurpose grease to seal surface of "U" packing.

Apply transmission fluid to cross shaft teeth and side cover "O" ring.

Install cross shaft to side cover, and temporarily tighten adjusting

bolt lock nut.

CAUTION: DO NOT rotate side cover during installation, or damage to

         cross shaft oil seal may result.

         9) Apply transmission fluid to rack piston teeth and shaft

areas. Apply multipurpose grease to oil seal lip. Install side cover

assembly (with cross shaft) to gearbox.

         10) Position mainshaft in straight-ahead position. While

turning adjusting bolt, measure mainshaft combined starting torque

using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.

Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center

reading should be 2 INCH lbs. (.2 N.m) higher than reading at either

end.

         11) Tighten adjusting bolt lock nut to specification. See

TORQUE SPECIFICATIONS. Install pitman arm with mating marks aligned.

         POWER STEERING PUMP

         Disassembly

         1) Remove suction connector bolts. Mount pump in a soft-jawed

vise. Remove pump cover bolts and cover. Using a plastic mallet, tap

pulley assembly shaft from pump housing. See  Fig. 4.

         2) Remove cam ring, vanes, shaft assembly and "O" rings.

Remove snap ring from shaft assembly. Remove collar, rotor and side

plate from shaft.

         3) Pry oil seal out of housing. Remove pressure connector.

Remove flow control valve assembly, flow control spring and 2 "O"

rings. DO NOT disassemble flow control valve assembly.

Fig. 4:  Exploded View Of Power Steering Pump

Courtesy of Mitsubishi Motor Sales of America.

         Inspection

         1) Inspect pump shaft oil seal lip and bushing end for

damage. Inspect groove of rotor vane and cam surface for stepped wear.

Check vane for damage. Install vane into rotor groove. Measure

clearance between vane and rotor groove. If clearance exceeds .0024"

(.061 mm), replace entire assembly.

         2) Check ring and rotor sides for damage. Replace entire

assembly if any damage is present. Check sliding surfaces of control

valve for obstructions. Replace parts as required. If control valve is

replaced, always use valve with same identification mark as one being

replaced. Check power steering fluid pressure.

         Reassembly

         1) Lubricate "O" rings and internal pump components with ATF

before reassembly. Install flow control valve spring and control valve

in housing.

         2) Install and tighten pressure connector. Depress control

valve to check for smooth operation. Apply grease to lip of oil seal.

Install oil seal into pump body. Install pulley assembly into pump

body.

         3) Install rotor to pulley assembly with punch mark at pump

cover side. Install snap ring. Lift rotor to ensure that snap ring is

in countersunk part of shaft. Align cam ring dowel holes and install

cam ring with punch mark on pump body side.

         4) Apply transmission fluid to vanes, and install vanes onto

rotor with rounded edges outward. Install "O" ring, cam case and pump

cover. Install and tighten suction connector.

         TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application                                             Ft. Lbs. (N.m)

Adjusting Bolt Lock Nut  ....................................  27 (37)

Idler Arm Bracket-To-Frame Bolt & Nut

  Montero  ............................................  40-47 (54-64)

  Montero Sport  ............................................  43 (59)

Idler Arm-To-Bracket Lock Nut  .............................  101 (44)

Oil Pump Cover Bolts  .......................................  15 (20)

Pitman Arm-To-Cross Shaft Nut

  Montero  ........................................  108-123 (146-176)

  Montero Sport  ..................................  108-123 (147-167)

Pressure Hose In-Line Fitting

  Montero  ..................................................  25 (34)

  Montero Sport  ............................................  16 (22)

Relay Rod-To-Idler Arm Nut  .................................  33 (44)

Relay Rod-To-Pitman Arm Nut  ................................  33 (44)

Side Cover Bolts

  Montero  ..................................................  36 (49)

  Montero Sport  ......................................  41-47 (50-64)

Steering Gear Hose Fittings  ................................  11 (15)

Steering Gear-To-Frame Bolts  .........................  40-47 (54-64)

Tie Rod Adjusting Sleeve Lock Nuts  .........................  69 (93)

Tie Rod End Castle Nuts  ....................................  33 (44)

Valve Housing Bolts

  Montero  ..................................................  36 (49)

  Montero Sport  ......................................  41-47 (56-64)

Valve Housing Lock Nut  .........................................  ( 1)

(1) - Tighten lock nut until it contacts bearing race.