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Mitsubishi Outlander (2003+). Manual - part 291

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-23

LUBRICATION AND SEALING POINTS

AC200119 AC

Grease: Silicone grease

Fluid:
ATF DXRON III or
DEXRON II

Grease: Repair kit grease
Fluid:
ATF DXRON III or
DEXRON II
Sealant:
3M ATD Part No. 8661, 8663
or equivalent

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

Fluid:
ATF DXRON III or
DEXRON II

Grease: Repair kit grease
Fluid:
ATF DXRON III or DEXRON II

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-24

DISASSEMBLY SERVICE POINTS

<<A>> RACK SUPPORT COVER REMOVAL

Using special tool rack support cover wrench
(MB991621), remove the rack support cover from the
steering gear.

<<B>> LOWER OIL SEAL/PINION AND VALVE
ASSEMBLY REMOVAL

Using a plastic hammer, gently tap the pinion to
remove it.

<<C>> SEAL RING REMOVAL

CAUTION

When cutting the seal ring, be careful not to
damage the pinion and valve assembly or the
rack.

Cut the seal ring and remove it from the pinion and
valve assembly or the rack.

<<D>> UPPER BEARING/UPPER OIL SEAL
REMOVAL

Using a socket, remove the oil seal and the ball
bearing from the valve housing simultaneously.

<<E>> CIRCLIP REMOVAL

CAUTION

If the rack stopper is first turned counterclockwise,
the circlip will get caught in the slot in the housing
and the rack stopper will not turn.

1. Turn the rack stopper clockwise until the end of

the circlip comes out of the slot in the rack
housing.

2. Turn the rack stopper counterclockwise to remove

the circlip.

<<F>> RACK STOPPER/RACK BUSHING/OIL
SEAL/O-RING/RACK ASSEMBLY REMOVAL

1. Pull out the rack slowly. Take out the rack stopper

and the rack bushing at the same time.

AC103692 AB

MB991621

ACX01143 AB

ACX01144 AB

ACX01145AC

Socket

ACX01146 AB

Circlip

Rack stopper

ACX01147 AB

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-25

CAUTION

Do not damage the oil seal press fitting surface.

2. Partially bend the oil seal and remove it from the

rack bushing.

<<G>> LOWER BEARING REMOVAL

Use a brass bar or special tool brass bar
(MB990939) to remove the ball bearing from the gear
housing.

<<H>> NEEDLE BEARING REMOVAL

CAUTION

Do not open special tool excessively to prevent
damaging housing interior.

Use special tool needle bearing puller (MB991120)
to remove the needle bearing from the rack housing.

<<I>> OIL SEAL REMOVAL

CAUTION

Be careful not to damage the inner surface of the
rack cylinder of the gear housing.

Use a piece of pipe or similar tool to remove the oil
seal from the gear housing.

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION
1. Apply a coating of ATF DEXRON III or DEXRON II

to the both sides of the oil seal.

2. Using the following special tools, press the oil seal

into the rack housing.

MB991197: Bar (Long type)

MB991199: Oil Seal and Bearing Installer

>>B<< NEEDLE BEARING/LOWER BEARING
INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing,

bearing and oil seal press fitting surface.

ACX01148 AB

Rack bushing

ACX01149

MB990939

Lower bearing

Valve housing

ACX01150 AB

Valve housing

MB991120

Needle
bearing

AC100259

Oil seal

Pipe or similar tool

Gear housing

AC100260 AC

MB991197

Oil seal

MB991199

Gear housing

POWER STEERING GEAR BOX AND LINKAGE

POWER STEERING

37-26

CAUTION

Press-fit straight. The valve housing is
aluminium, and may become deformed if press-
fit on an angle.

2. Press fit needle bearing with the following special

tools.

MB990938: Bar (Snap-in type)

MB991202: Oil Seal and Bearing Installer

>>C<< RACK ASSEMBLY INSTALLATION

CAUTION

Do not close the vent hole in the rack with
grease.

1. Apply a coating of repair kit grease to the rack

teeth face.

2. Cover rack serrations with special tool rack

installer (MB991213).

3. Apply ATF DEXRON III or DEXRON II to special

tool, and to the outer surface of the seal ring and
the O-ring.

4. Align the centre of the oil seal with the rack to

prevent the retainer spring from slipping. Slowly
insert the rack from power cylinder side.

>>D<< OIL SEAL/RACK BUSHING INSTALLATION

1. Apply ATF DEXRON III or DEXRON II to the outer

surface of the oil seal. Using the special tool
installer adapter (MB990927), press in the oil seal
until it is flush with the bushing end face.

2. Apply ATF DEXRON III or DEXRON II to the oil

seal inner surface and the O-ring.

3. Wrap the rack end with plastic tape, and push the

rack bushing onto the rack.

>>E<< CIRCLIP INSTALLATION

CAUTION

Insert the circlip to the rack stopper hole while
turning the rack stopper clockwise.

Insert the circlip to the rack stopper hole through
cylinder hole. Turn the rack stopper clockwise and
insert the circlip firmly.

ACX01153

Needle bearing

MB990938

MB991202

Lower
bearing

MB990938

ACX01154 AB

Seal ring and O-ring

Vent hole

ACX01155

MB991213

Oil seal

ACX01156 AE

Oil seal

O-ring

MB990927

Rack
bushing

AC100261AB

Rack

Vinyl tape

Rack bushing

ACX01158

Circlip

Slot

Circlip

Slot

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