REMOVAL AND INSTALLATION
| WARNING | Before removing the steering wheel - driver's air bag module assembly, refer to DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING . When removing and installing the steering wheel, do not let it bump against the air bag module. |
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Required Special Tool
- MB990784: Ornament remover
<< A >> STEERING WHEEL REMOVAL
Insert special tool MB990784 at the indicated position to remove the cover.
Note. Special tool MB990784 can be inserted through the notch behind the area shown.
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- By sliding section A of the clock spring connector shown in the illustration in the arrow direction, disconnect the connector.
- Loosen the bolt completely. Then, remove the steering wheel and airbag module assembly. NOTE: Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm (3.0 inches) or more in the hexagonal section and the diameter of 8 mm (0.31 inches) or more.
| WARNING | Before removing the steering wheel - driver's air bag module assembly, refer to DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING . |
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<< A >> STEERING COLUMN SHAFT ASSEMBLY REMOVAL
| CAUTION | The tilt lever should be held in the lock position until the steering column shaft is installed to the vehicle. If the steering column is removed with the tilt lever released, or the tilt lever is released after the steering column shaft was removed from the vehicle, the steering column can not be reinstalled correctly. If the steering column is installed incorrectly, the collision energy absorbing mechanism may be damaged. |
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- Ensure that the tilt lever is in the lock position, and remove the steering column mounting bolts.
- Pinch the steering column shaft clip with pliers, and pull up the shaft towards the direction shown to disengage the steering column shaft assembly.
>> A << STEERING COLUMN SHAFT ASSEMBLY INSTALLATION
| CAUTION | When reusing the steering column, do not release the tilt lever until the steering column shaft has been installed. When the steering column is replaced, do not release the tilt lever until it has been installed. Do not remove the tilt lever fixing band until the installation has completed. When installing the steering column, do not leave it fixed temporarily at only one point and make sure the column shaft is not shaken strongly. If you fail to do, the collision absorbing mechanism at the column shaft mounting location may be damaged. |
Ensure that the tilt lever is in the lock position, and install the steering column. Tighten the four bolts in the order shown by hand, and then tighten them to the specified torque in the order shown.
- Tightening torque: 12+/-2 N.m (102+/-22 in-lb)
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>> A << STEERING LOCK CYLINDER ASSEMBLY/STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION
| CAUTION | The bolts must be replaced with new ones when the steering lock is installed. |
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- When installing the steering lock cylinder and steering lock bracket to the steering column assembly, temporarily install the steering lock in alignment with the column boss.
- After checking that the lock works properly, tighten the special bolts until the head is twisted off.
| WARNING | Before removing the steering gear, refer to DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING . Center the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury. |
| CAUTION | 1: Indicates parts which should be temporarily tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. 2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. During maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. And if there is brake fluid on the caliper, wipe out quickly. |
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Required Special Tool
- MB991897: Ball Joint Remover
<< A >> LOWER ARM ASSEMBLY REMOVAL
Lift the transaxle with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly.
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<< C >> FRONT AXLE NO.1 CROSSMEMBER ASSEMBLY REMOVAL
Retain the crossmember with a transmission jack, and then remove the crossmember mounting bolt.
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>> A << JOINT COVER GROMMET INSTALLATION
Align the joint cover grommet notch (arrow A) with the steering gear lug (arrow B), and then install the steering joint cover to the steering gear.
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<< A >> RACK SUPPORT COVER REMOVAL
Using special tool MB991204, remove the rack support cover from the gear box.
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<< B >> LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
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<< 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 and the rack.
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<< D >> UPPER BEARING/UPPER OIL SEAL REMOVAL
Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
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<< 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. |
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- Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
- Turn the rack stopper counterclockwise to remove the circlip.
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- Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time. CAUTION: Do not damage the oil seal press fitting surface.
- Partially bend the oil seal and remove it from the rack bushing.
<< G >> LOWER BEARING REMOVAL
Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.
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<< H >> NEEDLE BEARING REMOVAL
| CAUTION | Do not open special tool MB991120 excessively to prevent damaging housing interior. |
Use special tool MB991120 to remove the needle roller bearing from the rack housing.
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<< 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.
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- Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the both sides of the oil seal.
- Using special tools MB991199 and MB991197, press the oil seal into the rack housing.
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- Apply GENUINE MITSUBISHI POWER STEERING FLUID to housing, bearing and oil seal press fitting surface. CAUTION: Press-fit straight. The valve housing is aluminum, and may become deformed if press-fit on an angle.
- Press fit needle roller bearing with special tools MB990938 and MB991202.
>> C << RACK ASSEMBLY INSTALLATION
| CAUTION | Do not close the vent hole in the rack with grease. |
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- Apply a coating of multipurpose grease to the rack teeth face.
- Cover rack serrations with special tool MB991214.
- Apply GENUINE MITSUBISHI POWER STEERING FLUID to special tool MB991214.
- Align the center of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side.
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- Apply GENUINE MITSUBISHI POWER STEERING FLUID to the outer surface of the oil seal. Using special tool MB990927, press in the oil seal until it is flush with the bushing end face.
- Apply GENUINE MITSUBISHI POWER STEERING FLUID to the oil seal inner surface and the O-ring.
- 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.
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>> F << UPPER OIL SEAL/UPPER BEARING INSTALLATION
Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the outside of the upper oil seal/upper bearing. Using special tools MB990938 and MB991203, press the upper oil seal/upper bearing into the valve housing.
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>> G << SEAL RING INSTALLATION
Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the rings, or press down by hand.
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>> H << LOWER OIL SEAL INSTALLATION
| CAUTION | To eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm (0.04 inch) from the housing edge surface. |
Using special tool MB990941, press the oil seal into the valve housing.
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- Apply 3M™ AAD Part number 8661, 8663, 8672, 8678, 8679 or equivalent to the threaded part of the end plug.
- Secure the threaded portion of the end plug at two places by using a punch.
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- Position the rack at its center.
- Apply 3M™ AAD Part number 8661, 8663, 8672, 8678, 8679 or equivalent to the threaded part of the rack support cover.
- Use special tool MB991204 to tighten the rack support cover to 23+/-2 N.m (17+/-1 ft-lb).
- Turn the rack support cover 30 degree angle counterclockwise.
- Use special tool MB991204 to hold the rack support cover, and then tighten the jam nut to 59+/-10 N.m (44+/-7 ft-lb).
>> L << GEAR MOUNTING RUBBER INSTALLATION
Install the gear mounting rubber to the rack housing so that the distance is as shown in the illustration.
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>> M << TAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold tab washer end (two locations) to tie rod notch.
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- Turn the adjusting bolt of special tool MB991561 to adjust the opening dimension (W) to the standard value. NOTE: The dimension (W) is adjusted by approximately 0.7 mm (0.03 inch) per one turn. NOTE: Do not turn the adjusting bolt more than one turn. Standard value (W): 2.9 mm (0.11 inch) < When more than 2.9 mm (0.11 inch) >: Screw in the adjusting bolt. < When less than 2.9 mm (0.11 inch) >: Loosen the adjusting bolt. CAUTION: Hold the rack housing, and use special tool MB991561 to crimp the bellows band securely. Crimp the bellows band until special tool MB991561 touches the stopper.
- Use special tool MB991561 to crimp the bellows band.
- Check that crimped width (A) is within the standard value. Standard value (A): 2.4 - 2.8 mm (0.09 - 0.11 inch) < When more than 2.8 mm (0.11 inch) >: Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 2.9 mm (0.11 inch), (W) is 2.6 mm (0.10 inch).] < When less than 2.4 mm (0.09 inch) >: Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 2.3 mm (0.09 inch), (W) is 3.2 mm (0.13 inch).]
>> O << TIE ROD END/JAM NUT INSTALLATION
Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut.
Note. The locking nut must be tightened securely only after the power steering gear box and linkage are installed to the vehicle and toe-in is adjusted.
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TIE ROD END BALL JOINT DUST COVER REPLACEMENT
If the dust cover is damaged accidentally during service work, replace the dust cover as follows
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- Apply grease to the lip and inside of the dust cover.
- Drive in the dust cover with special tool MB990776 until it is fully seated.
- Check the dust cover for cracks or damage by pushing it with your finger.
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- Install the pressure hose so that the notch is fixed with bracket as shown in the illustration.
- Install the suction hose so that the marking is positioned as shown in the illustration.
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<< A >> EYE BOLT/RETURN TUBE REMOVAL
- Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so that the eye bolts or return tube at the steering gear side can be removed. NOTE: In this case, do not remove the crossmember mounting bolts and nuts.
- Remove the eye bolts or return tube.
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- Install the return hose so that the marking is positioned as shown in the illustration.
- Install the clip as shown in the illustration.
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- Install the pressure hose on pump side so that the notch is fixed with bracket as shown in the illustration.
- Install the suction hose so that the marking is positioned as shown in the illustration.
- Install the pressure hose on gear box side so that its plate part is positioned as shown in the illustration.
>> C << RETURN HOSE INSTALLATION
Install the return hose so that the marking is positioned as shown in the illustration.
