power steering MITSUBISHI LANCER IX 2006 Owner's Guide

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-25
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 neces
-
sary.
TIE ROD SWING RESISTANCE CHECK
1. Give 10 hard swings to the tie rod.
AC000997
2. Measure the tie ro d swin g resist ance [tie rod
swing to rque] with a spring bala n ce.
St andard va lue: 8 − 27 N [1.5 − 4.9 N⋅m]
3.If the measu r ed value exceeds the st a ndard
value , replace the tie rod.
4. If the measured value is below the st a ndard valu e,
th e tie rod can be re-use d if it swings smo o thly
wit hout e xce ssive play .
TIE ROD END BALL JOINT DUST COVER
CHECK
1.Check t he dust co ver f o r cracks or da mage by
p u shing it with your finger .
2.If the du st cover is cracked o r damaged, repla c e
th e tie rod end (Refer to
P.37-26).
NOTE: Cracks or dama ge of t he dust co ver may
d
a
mag
e the ball joint. If it is da mag ed du ring serv
-
ice work, replace the du st cove r (Re f er to
P.37-35).

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-26
DISASSEMBLY AND REASSEMBLY
M1372011100193
<LH drive vehicles>
AC100244AC
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·m 25 ± 4 N·m
18
24
23
20
19
21
22
13
34 4
4
3
1 36
216
30
31
32
27
29
28
25 26
1188 ± 10 N·m
10
8
9
7
5
6
52 ± 2 N·m
35
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 nut
18.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 housing
Disassembly steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-27
<RH drive vehicles>
AC102865
3
23
21
19 4
11 8
8 11 35
17 3132 29
28
6
5
7
9
8
10
11
25
26
28 29
27
32
31
30 12
13
14
15
16
17 33
35
36 1
4
2
34
4 4
3
24
23
22
21 20
19
18
AD
Steering gear seal kit
Flare nut
Repair kit grease
22 ± 4 N·m
59 ± 10 N·m
25 ± 4 N·m
88 ± 10 N·m52 ± 2 N·m
59 ± 10 N·m 13 ± 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 nut
18.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 housing
Disassembly steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-28
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
or equivalent
Grease:
Multipurpose grease
SAE J310, NLGI No.2
or equivalent
Fluid:
ATF DXRON III or
DEXRON II
Fluid:
ATF DXRON III or
DEXRON II
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 STEERING37-29
DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER
REMOVAL
AC209838
MB990607
AK
<Invite>
AC103692AI
MB991621
<Intense>
Using
the followin g sp ecial too l , remove the ra ck
supp
ort co ver fro m the stee ring gear .
•To rque wren ch socket (MB990607 ) <Invite>
•Piston driver (MB9916 21) <In t ense >
<<B>> LOWER OIL SEAL/PINION AND
V
A L V E ASSEMBL Y REMOV A L
ACX01143AB
Using a pla s tic hamme r , gently t ap t he pinion to
remove it.
<<C>> SEAL RING REMOVA L
CAUTION
When cutting the seal ring, be careful not to dam-
age the pinion and valve assembly or the rack.
ACX01144
AB
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
<<D>> UPPER BE ARING/UPPER OIL
SEAL REMOVAL
ACX01145 AC
Socket
Using a socket, remove the oil seal and the ball bear-
ing from the valve housing simultaneously.
<<E>> CIRCLIP REMOVAL
CAUTION
If the rack stopper is first turned anticlockwise,
the circlip will get caught in the slot in the hous
-
ing and the rack stopper will not turn.
ACX01146
AB
Circlip
Rack stopper
1. Turn the rack stopper clockwise until the end of
the circlip comes out of the slot in the rack
housing.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-30
2. Turn the rack stopper anticlockwise to remove the circlip.
<<F>> RACK STOPPER/RACK
BUSHING/OIL SEAL/O-RING/RACK
ASSEMBLY REMOVAL
ACX01147 AB
1.
Pull out th e rack slo w ly . T a ke out th e rack stop per
an d the rack bushing at the same time.
CAUTION
Do not damage the oil seal press fitting surface.
ACX01148AB
Rack bushing
2. Partially bend the oil seal and remove it from the
rack bushing.
<<G>> LOWER BEARING REMOVAL
ACX01149
MB990939
Lower bearing
AC
Valve housing
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.
ACX01150 AB
Valve housing MB991120Needle
bearing
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.
AC100259
Oil seal
Pipe or similar tool
Gear housing
AB
Use a piece of pipe or simila
r 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.
AC100260AI
Oil seal
MB991202 <Invite>
MB991199 <Intense>
Gear housing
MB991197
2. Using the following special tools, press the oil seal
into the rack housing.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-31
•Bar (long type) (MB991197)
•Oil seal installer (MB991199) <Intense>
•Oil seal and bearing installer (MB991202)
<Invite>
>>B<< NEEDLE BEARING/LOWER
BEARING INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing and bearing press fitting surface.
CAUTION
Press-fit straight. The valve housing is alumin-
ium, and may become deformed if press-fit on an
angle.
ACX01153
Needle bearing
MB990938
MB991202 MB991202
Lower
bearing
AE
MB990938
2. Press fit needle bearing/lower bearing with the
following special tools.
•Bar (snap-in type) (MB990938)
•Oil seal and bearing installer (MB991202)
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not close the vent hole in the rack with
grease.
ACX01154 AB
Seal ring and O-ring Vent hole
1. Apply a coating of repair kit grease to the rack
teeth face.
ACX01155
MB991212 <Invite>
MB991213 <Intense>
AJ
Oil seal
2. Cover rack serrations with the following special tool.
•Oil seal protector (MB991212) <Invite>
•Oil seal protector (MB991213) <Intense>
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
ACX01156 AE
Oil seal
O-ring
MB990927
Rack
bushing
1. Apply ATF DEXRON III or DEXRON II to the outer surface of the oil seal. Using special tool installer
adapter (MB990927), press in the oil seal until it is
flush with the bushing end face.
AC100261 AC
Rack
Plastic tape
Rack bushing
2. Apply ATF DEXRON III or DEXRON II to the oil seal inner surface and the O-ring.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-32
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.
ACX01158
Circlip
Slot
AB
Circlip
Slot
Insert the circlip to the rack stopper hole through cyl-
inder hole. Turn the rack stopper clockwise and
insert the circlip firmly.
>>F<< UPPER OIL SEAL/UPPER
BEARING INSTALLATION
ACX01159AC
MB990938
MB991203
Oil seal
MB991203 Bearing
MB990938
Apply a coating of ATF DEXRON III or DEXRON II to
the outside of the upper oil seal/upper bearing. Using
the following special tools, press the upper oil
seal/upper bearing into the valve housing.
•Bar (snap-in type) (MB990938)
•Oil seal and bearing Installer (MB991203)
>>G<< SEAL RINGS INSTALLATION
ACX01160
AB
MB991317
Because the seal rings expand after installation,
tighten after installing by using special tool seal ring
installer (MB991317) to compress the rings, or press
down by hand.
>>H<< LOWER OIL SEAL INSTALLATION
ACX01161
Housing
AC
Oil
seal
Approximately
1 mm
MB990941
CAUTION
To eliminate a seal malfunction at the valve hous-
ing alignment surface, the upper surface of the
oil seal should project outward approximately 1
mm from the housing edge surface.
Using special tool torque tube bearing installer
(MB990941), press the oil seal into the valve hous
-
ing.
>>I<< END PLUG INSTALLATION
ACX01162
AB
End plug End plug
1. Apply specified sealant to the threaded part of the
end plug.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-33
Specified sealant: 3M ATD Part No.8661 or
equivalent
2. Secure the threaded portion of the end plug at two places by using a punch.
>>J<< RACK SUPPORT COVER/LOCK
NUT INSTALLATION
1. Position the rack at its centre.
2. Apply specified sealant to the threaded part of the
rack support cover.
Specified sealant:
3M ATD Part No.8661 or equivalent
AC100273
MB990607 <Invite>
MB991621 <Intense>
AJ
3.Use the fo llo wing special to ol to tigh ten the rack
suppor t cover to 2 3
± 2 N⋅m.
•To rque wren ch socket (MB990607 ) <Invite>
•Piston driver (MB9916 21: <In t ense>
4.T u rn the rack suppo rt cover 30° anticlockwise .
5.Use the special tool to hold the r a ck sup port
cove r , and t hen tighten the lock nut to 59
± 10
N
⋅m.
>>K<< T O T A L PINION T O RQUE
ADJUSTMENT
CAUTION
•Be sure there is no ratcheting or catching
when operating the rack towards the shaft.
•
AC100274 AB
MB991006
Measure the total pinion torque through the
whole stroke of the rack.
1. Using special tool preload socket (MB991006),
rotate the pinion shaft at the rate of one rotation in
4 to 6 seconds to check the total pinion torque and
the change in torque.
Standard value:
Total pinion torque: 0.8 − 2.1 N⋅m <Invite>
[Change in torque: 0.6 N
⋅m or less]
Total pinion torque: 0.7 − 2.1 N⋅m <Intense>
[Change in torque: 0.6 N
⋅m or less]
CAUTION
When adjusting, set at the highest value of the
standard value range.
NOTE: If the total pinion toque cannot be adjusted
to the standard value within the specified return
angle, check the rack support cover components
and replace any parts if necessary.
2. If the total pinion torque or the change in torque is outside the standard value, move the rack support
cover 0
− 30°, and adjust the pinion torque again.
>>L<< TAB WASHER/TIE ROD
INSTALLATION
ACX01163 AB
After installing the tie rod to the rack, fold tab washer
end (two locations) to tie rod notch.
>>M<< BELLOWS BAND INSTALLATION
ACX01164 AB
W MB991561
Adjusting bolt Stopper
1. Turn the adjusting bolt of special tool boot band
crimping tool (MB991561) to adjust the opening
dimension (W) to the standard value.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-34
NOTE: The dimension (W) is adjusted by approxi-
mately 0.7 mm per one turn.
NOTE: Do not turn the adjusting bolt more than
one turn.
Standard value (W): 2.9 mm
<When more than 2.9 mm>: Screw in the
adjusting bolt.
<When less than 2.9 mm>: Loosen the
adjusting bolt.
CAUTION
•Hold the rack housing, and use special tool to
crimp the bellows band securely.
•
ACX01165AB
MB991561
Crimp the bellows band until special tool
touches the stopper.
2. Use special tool boot band crimping tool (MB991561) to crimp the bellows band.
ACX01166 AB
A
3. Check that crimped width (A) is within the
standard value.
Standard value (A): 2.4 − 2.8 mm
<When more than 2.8 mm>: Readjust the
dimension (W) of step (1) to the value calcu
-
lated by the following equation, and repeat
step (2).
W = 5.5 mm − A [Example: if (A) is 2.9 mm,
(W) is 2.6 mm.]
<When less than 2.4 mm>: Remove the bel-
lows band, readjust the dimension (W) of
step (1) to the value calculated by the follow
-
ing equation, and use a new bellows band to
repeat steps (2) to (3).
W = 5.5 mm − A [Example: if (A) is 2.3 mm,
(W) is 3.2 mm.]
>>N<< TIE ROD END/LOCK NUT
INSTALLATION
AC001011 AM
Lock nut
Edge of bellows
assembly groove
180 mm
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut.
NOTE: The lock nuts must be tightened securely
only after the steering gear is installed to the vehicle
and toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER
INSTALLATION
AC100275 AB
220 mm
Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.