Mitsubishi Montero (2002-2004). Manual - part 435

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-27

POWER STEERING GEAR BOX ASSEMBLY

REMOVAL AND INSTALLATION

M1372003900235

WARNING

Before removing the steering gear box, refer to GROUP 52B. Center the front wheels and 
remove the ignition key. Failure to do so may damage the SRS clock spring and render the 
SRS system inoperative, risking serious injury.

Required Special Tool:

• MB991897: Ball Joint Remover

Pre-removal Operation
Power Steering Fluid Draining (Refer to 

P.37A-19

.)

Post-installation Operation
• Fill power steering fluid and bleed air (Refer to 

P.37A-19

.)

• Check the Dust Cover for Cracks or Damage by Pushing 

it with Your Finger.

• Check the steering angle (Refer to 

P.37A-16

.)

AC000760

71 

± 

7 N

·

m

53 

± 

5 ft-lb

18 

± 

2 N

·

m

13 

± 

2 ft-lb

39 

± 

5 N

·

m

29 

± 

3 ft-lb

69 

± 

10 N

·

m

51 

± 

7 ft-lb

69 

± 

10 N

·

m

51 

± 

7 ft-lb

12 

± 

2 N

·

m

107 

± 

17 in-lb

12 

± 

2 N

·

m

107 

± 

17 in-lb

2

2

6

3

4

7

8

5

1

AB

15 

± 

3 N

·

m

11 

± 

2 ft-lb

REMOVAL STEPS

•

REMOVAL OF UNDER COVER

<<A>>

1. TIE ROD END AND KNUCKLE 

CONNECTION

2. BOLT

>>B<<

3. PRESSURE HOSE ASSEMBLY

>>B<<

4. RETURN TUBE 

>>A<<

5. TIE ROD END (LH)

<<B>>

•

INSTALLATION OF DIFFERENTIAL 
MOUNT BRACKET (LH)

6. STEERING SHAFT ASSEMBLY AND 

GEAR BOX CONNECTING BOLT

7. GEAR BOX CLAMP

<<C>>

8. GEAR BOX ASSEMBLY

REMOVAL STEPS (Continued)

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-28

REMOVAL SERVICE POINTS

.

<<A>> TIE ROD END AND KNUCKLE DISCONNECTION

CAUTION

• Do not remove the nut from ball joint. Loosen it and use 

special tool MB991897 to avoid possible damage to ball 
joint threads.

• Hang special tool MB991897 with a cord to prevent it 

from falling. 

1. Install special tool MB991897 as shown in the figure.

2. Turn the bolt and knob as necessary to make the jaws of 

special tool MB991897 parallel, tighten the bolt by hand and 
confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make sure the 
knob is in the position shown in the figure.

3. Tighten the bolt with a wrench to disconnect the tie rod end.

.

<<B>>REMOVAL OF DIFFERENTIAL MOUNT BRACKET 
ASSEMBLY (LH)
Remove the connection bolt for the front frame assembly and 
the differential mount bracket assembly.

.

AC106820 AB

CORD

BOLT

MB991897

NUT

BALL JOINT

AC106821

KNOB

PARALLEL

BOLT

GOOD

BAD

AB

AC000662AB

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-29

<<C>> GEAR BOX ASSEMBLY REMOVAL

CAUTION

Be sure not to damage the bellows and the tie rod end dust 
cover when removing the gear box assembly.

INSTALLATION SERVICE POINTS

.

>>A<< TIE ROD END (LH) INSTALLATION
Screw the tie rod to the dimension shown in the illustration and 
secure it temporarily with the jam nut.
NOTE: Tighten the locknut to the specified torque after install-
ing the gearbox onto the body and adjusting the toe-in.

.

>>B<< RETURN TUBE/PRESSURE HOSE ASSEMBLY 
INSTALLATION
Align the markings at the gearbox side and the tube side.

INSPECTION

M1372011000130

GEAR BOX TOTAL PINION TORQUE CHECK

Required Special Tool:

• MB991006: Preload Socket

AC000663 AB

(2)

(1)

ACX01140AC

57 mm
(2.2 in)

JUM NUT

BELLOWS
END

AC000664 AB

MATING MARKS

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-30

CAUTION

When holding the steering gear box assembly in a vice, 
secure its mounting positions. If it is secured in any other 
place, the gear housing may become deformed or dam-
aged.
Using special tool MB991006, rotate the pinion gear at the rate 
of one rotation in approximately 4 to 6 seconds to check the 
total pinion torque.

Standard value: 0.6 

− 1.7 N⋅m (5.3 − 15.0 in-lb)

[Change in torque: 0.4 N

⋅m (3.5 in-lb) or less]

NOTE: When measuring, remove the bellows from the rack 
housing.
NOTE: Measure the pinion torque through the whole stroke of 
the rack.                                                                                                          
NOTE: If the measured value is not within the standard range, 
first adjust the rack support cover, and then check the total pin-
ion torque again.                                   
NOTE: If the total pinion torque cannot be adjusted to within the 
standard range by adjusting the rack support cover, check the 
rack support cover, rack support spring, rack support and 
replace any parts if necessary.

TIE ROD SWING RESISTANCE CHECK

1. Using a spring balance, give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance with a spring balance.

Standard value: 11 

− 35 N (35.4 − 82.7 lb) [1.4 − 4.9 N⋅m 

(12.4 

− 43.4 in-lb)]

3. If the measured value exceeds the standard value, replace 

tie rod.

4. If the measured value is below the standard value, the tie 

rod can be re-used if it swings smoothly without excessive 
play.

TIE ROD END BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing it 

with your finger.

2. If the dust cover is cracked or damaged, replace the tie rod 

end. (Refer to 

P.37A-27

.)

NOTE: Cracks or damage of the dust cover may damage 
the ball joint. If it is damaged during service work, replace 
the dust cover. (Refer to 

P.37A-43

.)

AC000665 AB

MB991006

ACX01141AB