Mitsubishi Montero Sport (2004+). Manual - part 829

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

STEERING

37A-39

>>F<< PITMAN ARM INSTALLATION
Install the pitman arm to the gear box with the mating marks 
aligned.

POWER STEERING GEAR BOX ASSEMBLY 
INSPECTION (DISASSEMBLY AND 
REASSEMBLY)

DUST COVER REPLACEMENT

M1372008200372

When the dust cover is damaged accidentally during service 
work, replace the dust cover only as follows:
1. Fill the dust cover with the specified grease, and apply the 

grease to the go to top of the dust cover and contact surface 
of the lip.

Specified grease: Multipurpose grease SAE J310, 
NLGI No.2 or equivalent

2. Apply the 3M

 AAD Part number 8672, 8679, 8678, 8661, 

8663 or equivalent to the mounting surface of the dust cover 
at the pitman arm.

3. Using special tool MB990776, install the dust cover to the 

pitman arm.

4. Press the dust cover with a finger to check whether the dust 

cover is cracked or damaged.

AC004357AB

MATING MARKS

AC103638

MB990776

AB

POWER STEERING OIL PUMP ASSEMBLY

TSB Revision

STEERING

37A-40

POWER STEERING OIL PUMP ASSEMBLY

REMOVAL AND INSTALLATION

M1372005200384

INSPECTION

M1372005300239

• Check the drive belt for cracks.

• Check the pulley assembly for uneven rotation.

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

P.37A-20

.)

Post-installation Operation
• Power Steering Fluid Level Check (Refer to 

P.37A-19

.)

• Drive Belt Tension Check (Refer to 

P.37A-19

.)

• Power Steering Fluid Line Bleeding (Refer to 

P.37A-20

.)

• Oil Pump Pressure Test (Refer to 

P.37A-21

.)

AC004402 AB

2

4

1

3

5

6

7

8

9

4.9 N·m
43 in-lb

24 N·m
17 ft-lb

22 N·m
16 ft-lb

44 N·m
33 ft-lb

44 N·m
33 ft-lb

49 - 64 N·m
36 - 47 ft-lb

N

REMOVAL STEPS

1. PULLY COVER
2. DRIVE BELT
3. PRESSURE SWITCH 

CONNECTOR

4. EYE BOLT

5. PRESSURE HOSE
6. GASKET
7. SUCTION HOSE
8. OIL PUMP
9. OIL PUMP BRACKET

REMOVAL STEPS (Continued)

POWER STEERING OIL PUMP ASSEMBLY

TSB Revision

STEERING

37A-41

DISASSEMBLY AND ASSEMBLY

M1372005400355

CAUTION

Do not disassemble the pressure switch assembly and valve subassembly.

AC103764

FLUID: GENUINE MITSUBISHI POWER 
STEERING FLUID

OIL PUMP SEAL KIT

OIL PUMP CARTRIDGE KIT

PULLEY AND SHAFT KIT

5

6

4

5

7

3

8

2

5

9

12

14

17

10

4

1

5

3

7

2

9

8

18

15

14

13

16

10

17

12

6

11

12 N·m
 104 in-lb

59 N·m
43 ft-lb

25 - 29 N·m
19 - 22 ft-lb

25 - 29 N·m
19 - 22 ft-lb

AD

N

N

N

N

N

N

POWER STEERING OIL PUMP ASSEMBLY

TSB Revision

STEERING

37A-42

Required Special Tools:

• MB990926: Installer Adapter

• MB990938: Bar (snap-in type)

DISASSEMBLY SERVICE POINT

.

<<A>> SNAP RING REMOVAL

ASSEMBLY SERVICE POINTS

.

>>A<< O-RING INSTALLATION

.

DISASSEMBLY STEPS

1. PUMP COVER

>>A<<

2. O-RING

>>F<<

3. VANES

>>E<<

4. CAM RING

<<A>> >>D<<

5. SNAP RING
6. PULLEY ASSEMBLY

>>C<<

7. ROTOR
8. SIDE PLATE

>>A<<

9. O-RING

>>B<<

10. OIL SEAL 
11. TERMINAL ASSEMBLY

>>A<<

12. O-RING

13. PLUG

>>A<<

14. O-RING
15. FLOW CONTROL SPRING
16. SUCTION CONNECTOR
17. O-RING
18. OIL PUMP BODY

DISASSEMBLY STEPS (Continued)

AC004405

NO.

ID 

× WIDTH mm (in)

1

21 

× 1.9 (0.8 × 0.07)

2

14.8 

× 2.4 (0.58 × 0.09)

3

3.8 

× 1.9 (0.15 × 0.07)

4

14.8 

× 1.9 (0.58 × 0.07)

5

15.8 

× 2.4 (0.62 × 0.09)

AC004404

CONNECTOR

SIDE PLATE

TERMINAL ASSEMBLY

1

2

3

4

5

AB

SUCTION CONNECTOR
MOUNTING PORTION
OF OIL BODY