power steering MITSUBISHI LANCER 2005 Owner's Guide

STEERING SHAFT
POWER STEERING37-22
2. Pinch the steering column shaft clip with pliers,
and pull up the shaft towards the direction shown
to disengage the steering column shaft assembly.
INSTALLATION SERVICE POINT
>>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
DISASSEMBLY AND REASSEMBLYM1372011700106
AC210969AD
Clip
Steering column
shaft
AC209383
AD
14
32
Tilt lever
AC210967AD
3 2 14
Disassembly steps
<<A>> >>A<<1. Special bolt
>>A<<2. Steering lock bracket
>>A<<3. Steering lock cylinder assembly
4. Steering column shaft assemblyDisassembly steps (Continued)

STEERING SHAFT
POWER STEERING37-23
DISASSEMBLY SERVICE POINT
<<A>> SPECIAL BOLT REMOVAL
1. Drill in the special bolt a hole deep enough for the
tap to stand.
2. Remove the special bolt with a left-hand tap.
REASSEMBLY SERVICE POINT
>>A<< STEERING LOCK CYLINDER
ASSEMBLY/STEERING LOCK
BRACKET/SPECIAL BOLT
INSTALLATION
CAUTION
The steering lock bracket and bolts must be
replaced with new ones when the steering lock is
installed.
1. When installing the steering lock cylinder
assembly and steering lock bracket to the column
tube, temporarily install the steering lock in
alignment with the column boss.
2. After checking that the lock works properly,
tighten the special bolts until the head twists off.
ACX01138
AB
Steering lock
bracket
Reverse screw tap
Special bolt
Steering lock
cylinder
ACX01139AB

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-24
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATIONM1372010900237
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and
Air Bag Module and Clock Spring (P.52B-210). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13.)Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
•Power Steering Fluid Supplying (Refer to P.37-13.)
•Power Steering Fluid Line Bleeding (Refer to P.37-13.)
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-5.)
AC304920
AB
57 ± 7 N·m
15 ± 3 N·m 70 ± 10 N·m
7
3 8
5
6
9
1024
1
12 ± 2 N·m
12 ± 2 N·m
<L.H. drive vehicles>
Removal steps
1. Crossmember (Refer to GROUP 32,
Crossmember P.32-8).
•Engine rear roll stopper bracket (Refer
to GROUP 32, Engine Roll Stopper
and Centermember P.32-7).
>>A<<2. Joint cover grommet
3. Return hose4. Return tube
5. O-ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkageRemoval steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-25
AC304921AC
57 ± 7 N·m15 ± 3 N·m
70 ± 10 N·m
3
52 4
1
<R.H. drive vehicles>
6
7
Removal steps
1. Crossmember (Refer to GROUP 32,
Crossmember P.32-8).
>>A<<2. Joint cover grommet
3. Return hose connection
4. Return tube5. Pressure hose connection
6. Clamp
7. Steering gear and linkageRemoval steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-26
INSTALLATION SERVICE POINT
>>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.
INSPECTIONM1372011000237
STEERING GEAR TOTAL PINION
TORQUE CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
Using special tool preload socket (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: 0.7 − 1.6 N⋅m
1300, 1600(Comfort): 0.8 − 2.1
1600(Sport), 2000: 0.7 − 2.1
[Change in torque: 0.6 N⋅m or less]NOTE: When measuring, remove the bellows from
the rack housing. Measure the pinion torque through
the whole stroke of the rack.
If the measured value is not within the standard
range, first adjust the rack support cover, and then
check the total pinion torque again.
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. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance [tie rod
swing torque] with a spring balance.
Standard value: 8 − 27 N [1.5 − 4.9 N⋅m]
3. If the measured value exceeds the standard
value, replace the 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.37-27).
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.37-36).
AC304922AB
A
B Joint cover
grommet
Steering gear
AC000996 AC
MB991006
AC000997

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-27
DISASSEMBLY AND REASSEMBLYM1372011100193
<L.H. drive vehicles>
AC100244AE
3
13 ± 3 N·m
Steering gear seal kit Flare nut
Repair kit grease
23
21
19
4
11
8
28 29
32 31 17 35
11 8
22 ± 4 N·m
59 ± 10 N·m
23 ± 2 N·m
-30˚
12
14
15
33
17
59 ± 10 N·m25 ± 4 N·m
18 24
23
20
19
2122
13 344
4
3
35
136
2
16
30 31
32
27
29 28
2526 1188 ± 10 N·m
10 8
9 7 5 6
40 ± 5 N·m
Disassembly steps
>>O<<1. Gear mounting rubber
2. Gear housing mounting bushing
3. Feed pipe
4. O-ring
>>N<<5. Lock nut
>>N<<6. Tie rod end
7. Clip
>>M<<8. Bellows band
9. Bellows
>>L<<10. Tie rod
>>L<<11. Tab washer
>>K<<•Total pinion torque adjustment
>>J<<12. Lock nut
<<A>> >>J<<13. Rack support cover
14. Support spring
15. Rack support
>>I<<16. End plug
17. Lock nut18. Valve housing assembly
<<B>> >>H<<19. Lower oil seal
<<B>>20. Pinion and valve assembly
<<C>> >>G<<21. Seal ring
<<D>> >>F<<22. Upper bearing
<<D>> >>F<<23. Upper oil seal
24. Valve housing
<<E>> >>E<<25. Circlip
<<F>>26. Rack stopper
<<F>> >>D<<27. Rack bushing
<<F>> >>D<<28. Oil seal
<<F>>29. O-ring
<<F>> >>C<<30. Rack assembly
<<C>>31. Seal ring
32. O-ring
<<G>> >>B<<33. Lower bearing
<<H>> >>B<<34. Needle bearing
<<I>> >>A<<35. Oil seal
36. Gear housingDisassembly steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-28
<R.H. drive vehicles>
AC102865
3
23
21
19
4
11
8
8
1135
17
31
3229
28
6 5 7
9 8 10 11
25 26
2829
27 32 31 3012
13 14 15
16 173335 361 4
2 3444
3 24
23
22
21
20
19
18
AE
Steering gear seal kit Flare nut
Repair kit grease 22 ± 4 N·m
59 ± 10 N·m 25 ± 4 N·m
88 ± 10 N·m
40 ± 5 N·m 59 ± 10 N·m13 ± 3 N·m
23 ± 2 N·m -30˚
Disassembly steps
>>O<<1. Gear mounting rubber
2. Gear housing mounting bushing
3. Feed pipe
4. O-ring
>>N<<5. Lock nut
>>N<<6. Tie rod end
7. Clip
>>M<<8. Bellows band
9. Bellows
>>L<<10. Tie rod
>>L<<11. Tab washer
>>K<<•Total pinion torque adjustment
>>J<<12. Lock nut
<<A>> >>J<<13. Rack support cover
14. Support spring
15. Rack support
>>I<<16. End plug
17. Lock nut18. Valve housing assembly
<<B>> >>H<<19. Lower oil seal
<<B>>20. Pinion and valve assembly
<<C>> >>G<<21. Seal ring
<<D>> >>F<<22. Upper bearing
<<D>> >>F<<23. Upper oil seal
24. Valve housing
<<E>> >>E<<25. Circlip
<<F>>26. Rack stopper
<<F>> >>D<<27. Rack bushing
<<F>> >>D<<28. Oil seal
<<F>>29. O-ring
<<F>> >>C<<30. Rack assembly
<<C>>31. Seal ring
32. O-ring
<<G>> >>B<<33. Lower bearing
<<H>> >>B<<34. Needle bearing
<<I>> >>A<<35. Oil seal
36. Gear housingDisassembly steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-29
LUBRICATION AND SEALING POINTS
AC200119AC
Grease: Silicone greaseFluid:
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 IIFluid:
ATF DXRON III or
DEXRON II
Fluid:
ATF DXRON III or
DEXRON IIGrease: Repair kit grease
Fluid:
ATF DXRON III or DEXRON II

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-30
DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER
REMOVAL
Using the following special tool, remove the rack
support cover from the steering gear.
•MB990607: Torque Wrench Socket <Comfort>
•MB991621: Piston Driver <Sport>
<<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.
AC209838
MB990607
AC
<Comfort>
AC103692AD
MB991621 <Sport>
ACX01143
AB
ACX01144
AB
ACX01145
AC
Socket

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-31
<<E>> CIRCLIP REMOVAL
CAUTION
If the rack stopper is first turned anticlockwise,
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 anticlockwise 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.
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 lower bearing from the
valve 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 valve 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.
ACX01146
AB
Circlip Rack stopper
ACX01147AB
ACX01148AB
Rack bushing
ACX01149
MB990939
Lower bearing
AC
Valve housing
ACX01150AB
Valve housingMB991120Needle
bearing
AC100259
Oil seal Pipe or similar tool Gear housing
AB