MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

STEERING – Power Steering Gear Box37A-11
FRACK STOPPER / RACK BUSHING / RACK
REMOVAL
Pull out the rack assembly gently, and remove the rack stopper
and rack bushing together.
GOIL SEAL REMOVAL
Partially bend the oil seal to remove from the rack bushing.
Caution
Do not damage the oil seal press fitting surface of the
rack bushing.
HBALL BEARING REMOVAL
Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
INEEDLE ROLLER BEARING REMOVAL
Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open the special tool excessively to prevent
damaging housing interior.
JOIL SEAL REMOVAL
Use a piece of pipe or similar tool to remove the oil seal
from the gear housing.
Caution
Be careful not to damage the inner surface of the rack
cylinder of the gear housing.
Rack bushing
Ball
bearing MB990939 or
brass bar
MB991120
Needle roller
bearing
Gear housing
Pipe or similar tool
Oil seal

STEERING – Power Steering Gear Box37A-12
REASSEMBLY SERVICE POINTS
AGEAR HOUSING MOUNTING RUBBER
INSTALLATION
1. Install the gear housing mounting rubber on the rack
housing so that the dimension shown is achieved.
NOTE
The gear housing mounting rubber can be installed
regardless of the installation direction of the slit.
2. Apply specified adhesive to the slit of the gear housing
mounting rubber.
Specified adhesive:
3M ATD Part No. 8155 or equivalent
BOIL SEAL INSTALLATION
CNEEDLE ROLLER BEARING / BALL BEARING
INSTALLATION
DRACK INSTALLATION
1. Apply a coating of repair kit grease to the rack tooth
face.
Caution
Do not close the vent hole in the rack with grease.
Slit Gear housing
mounting rubber3.1 mm
MB991452
Oil sealMB991197
(Bar)
Needle roller
bearing
MB990938
MB991202MB990938
MB991202
Ball bearing
Vent hole

STEERING – Power Steering Gear Box37A-13
2. Cover rack serrations with special tool.
3. Apply the specified fluid on the special tool.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
4. Match the oil seal centre with rack to prevent retainer
spring from slipping and slowly insert rack from power
cylinder side.
EOIL SEAL / RACK BUSHING INSTALLATION
1. Apply the specified fluid to the outer surface of the oil
seal. Press-fit the oil seal using the special tool until it
is flush with the bushing end face.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
FCIRCLIP INSTALLATION
Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
GOIL SEAL / BALL BEARING INSTALLATION
1. Apply a coating of the specified fluid to the outside of
the oil seal. Using the special tools, press the oil seal
into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
MB991214
Oil seal
Oil seal
MB990927
Rack
bushingO-ring
Rack bushingPlastic tape
Circlip
SlotCirclip
Slot
Oil sealMB990938
MB991203

STEERING – Power Steering Gear Box37A-14
2. Apply a coating of the specified fluid to the outside of
the ball bearing. Using the special tools, press the ball
bearing into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
HSEAL RING INSTALLATION
1. Kneed the seal ring to soften it.
2. Apply the specified fluid to the seal ring, and install to
the rack groove.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
IOIL SEAL INSTALLATION
Use the special tool to press the oil seal into the valve housing.
The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
JEND PLUG INSTALLATION
1. Apply the specified sealant to the threaded part of the
end plug.
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.
KTOTAL PINION TORQUE ADJUSTMENT
1. Position the rack at its centre. Tighten the rack support
cover to 15 Nm.
2. In neutral position, rotate the pinion shaft clockwise one
turn/4 – 6 seconds with the special tool. Return the rack
support cover 30 – 60 and adjust torque to the standard
value.
Ball bearingMB990938
MB991203
Pinion gearMB991317
Tapered side
Approx. 1 mmMB990941
End plug
SealantEnd plug
MB991006

STEERING – Power Steering Gear Box37A-15
3. Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
(1) When adjusting, set the standard value at its
highest value.
(2) Assure no ratcheting or catching when operating
the rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check or replace the rack support cover
components.
4. After adjusting, lock the rack support cover with lock nut.
LTAB WASHER / TIE-ROD INSTALLATION
After installing the tie-rod to the rack, fold the tab washer
end (2 locations) to the tie-rod notch.
MBELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
Standard value (W): 2.9 mm

Screw in the adjusting bolt.

Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by approx. 0.7 mm
per one turn.
(2) Do not turn the adjusting bolt more than one turn.
MB991006
MB991561
Stopper
Adjusting bolt W

STEERING – Power Steering Gear Box37A-16
2. Use the special tool to crimp the bellows band.
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.
3. Check that the crimped width (A) is within the standard
value.
Standard value (A): 2.4 – 2.8 mm

Readjust the dimension (W) of step (1) to the value
calculated 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.]

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 – A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
NTIE-ROD END / TIE-ROD END LOCKING NUT
INSTALLATION
Screw in the tie-rod end until the dimension shown is achieved.
Then, temporarily tighten with the locking 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.
TIE-ROD END BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease inside a new dust cover.
2. Using the special tool, press in the dust cover to the
tie rod end.
3. Check the dust cover for cracks or damage by pushing
it with finger.
MB991561
A
212 mm Edge of bellows
assembly grooveLock nut
MB990776

STEERING – Power Steering Gear Box37A-17
INSPECTION
RACK CHECK

Check the rack tooth surfaces for damage or wear.

Check the oil seal contact surfaces for uneven wear.

Check the rack for bends.
PINION AND VALVE ASSEMBLY CHECK

Check the pinion gear tooth surfaces for damage or wear.

Check for worn or defective seal ring.
BEARING CHECK

Check for roughness or abnormal noise during bearing
operation.

Check the bearing for play.

Check the needle roller bearing for roller slip-off.
OTHER CHECK

Check the cylinder inner surface of the rack housing for
damage.

Check the boots for damage, cracking or deterioration.

Check the rack support for uneven wear or dents.

Check the rack bushing for uneven wear or damage.

NOTES

42-1
BODY
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE OF CHANGE 2. . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM 2. . . . . . . . . .
SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 2. . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM 7. . . . . . . . . . . . . .
TRANSMITTER 7. . . . . . . . . . . . . . . . . . . . . . . . . .
SUNROOF 9. . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 9. . . . . . . . . . . . . .
SEALANT 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 9. . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 13. . . . . . . . . . . . . . . .
Water Test 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sunroof Fit Adjustment 13. . . . . . . . . . . . . . . . . . .
SUNROOF 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BODY – General / Keyless Entry System42-2
GENERAL
OUTLINE OF CHANGE

The descriptions of the troubleshooting using on MUT-II tester have been incorporated.
KEYLESS ENTRY SYSTEM
SPECIAL TOOL
ToolNumberNameUse
MB991502MUT-II sub assemblyRecording secret codes
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection procedure No.Reference page
None of the doors can be locked or unlocked using the transmitter.142-2
All of the doors can be locked and unlocked using the transmitter,
but the room lamp does not flash or illuminate. (However, the room
lamp operates normally when the doors are opened and closed.)242-4
Secret codes cannot be registered.342-4
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1
None of the doors can be locked or unlocked using the
transmitter.
Probable cause
The cause may be a malfunction of the transmitter, a malfunction of the receiver
or the lock and unlock signals are not being input to the ETACS-ECU.
Malfunction of transmitter

Malfunction of receiver

Malfunction of ETACS-ECU

Malfunction of wiring harness or connector

Malfunction of key reminder switch

Malfunction of door switch
NG
To next page
OK
Replace the transmitter battery. (Refer to P.42-7.)
Ye s
Has the secret code been registered properly? *NGRe-register the secret code. (Refer to P.42-8.)
Can the doors be locked and unlocked by the driver’s-side door
key cylinder and lock knob?NoCheck the centre door lock system.
NOTE
*: This should be done if a transmitter or receiver has been replaced, and if a secret code has not
been registered properly.