Mitsubishi Montero (2002-2004). Manual - part 436

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-31

DISASSEMBLY AND ASSEMBLY

M1372004100180

AC000761

24

23

22

21

20

24

19

26

27

28

29

30

18

17

16

15

14

25

13

12

11

10

9

8

7

6

5

31

32

33

34

35

36

37

4

4

3

3

2

1

4

11

8

18

3611

8

20

22

32

33

30

29

STEERING GEAR SEAL KIT

59 

± 

10 N•m

44 

± 

7 ft-lb

88 

± 

10 N•m

65 

± 

7 ft-lb

71 

± 

7 N•m

53 

± 

5 ft-lb

15 

± 

3 N•m

11 

± 

2 ft-lb

25 

± 

4 N•m

18 

± 

3 ft-lb

AC

FLARE NUT

22 

± 

4 N•m

16 

± 

3 ft-lb

12 

±

 

2 N

•

m

*

107 

±

 

17 in-lb

*

59 

± 

10 N•m

44 

± 

7 ft-lb

NOTE
*: Return the rack support cover - 10

DISASSEMBLY STEPS

>>O<<

1.

GEAR MOUNTING RUBBER

2.

GEAR HOUSING MOUNTING 
BUSHING

3.

FEED PIPE

4.

O-RING

>>N<<

5.

JAM NUT

>>N<<

6.

TIE ROD END

7.

CLIP

>>M<<

8.

BAND

9.

BELLOWS

>>L<<

10.

TIE ROD

>>L<<

11.

TAB WASHER

12.

COIL SPRING

>>K<<

•

TOTAL PINION TORQUE 
ADJUSTMENT

>>J<<

13.

LOCK NUT

<<A>> >>J<<

14.

RACK SUPPORT COVER

15.

SUPPORT SPRING

16.

RACK SUPPORT

>>I<<

17.

END PLUG

18.

LOCK NUT

19.

VALVE HOUSING ASSEMBLY

<<B>> >>H<<

20.

LOWER OIL SEAL

<<B>>

21.

PINION AND VALVE ASSEMBLY

<<C>> >>G<<

22.

SEAL RING

<<D>> >>F<<

23.

UPPER BEARING

DISASSEMBLY STEPS (Continued)

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-32

Required Special Tools:

• MB990927: Installer Adapter

• MB990938: Bar (Snap-in type)

• MB990939: Brass Bar

• MB990941: Torque Tube Bearing Installer 

• MB991006: Preload Socket

• MB991120: Needle Bearing Puller

• MB991152: Dust Cover Installer

• MB991197: Bar (Long type)

• MB991199: Oil Seal Installer

• MB991202: Oil Seal and Bearing Installer

• MB991203: Oil Seal and Bearing Installer

• MB991204: Torque Wrench Socket

• MB991213: Rack Installer

• MB991317: Seal Ring Installer

• MB991561: Boot Band Crimping Tool

<<D>> >>F<<

24.

UPPER OIL SEAL

25.

VALVE HOUSING

<<E>> >>E<<

26.

CIRCLIP

<<F>>

27.

RACK STOPPER

<<F>> >>D<<

28.

RACK BUSHING

<<F>> >>D<<

29.

OIL SEAL

<<F>>

30.

O-RING

<<F>> >>C<<

31.

RACK ASSEMBLY

<<C>>

32.

SEAL RING

33.

O-RING

<<G>> >>B<<

34.

LOWER BALL BEARING

<<H>> >>B<<

35.

NEEDLE BEARING

<<I>> >>A<<

36.

OIL SEAL

37.

GEAR HOUSING

DISASSEMBLY STEPS (Continued)

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-33

LUBRICATION AND SEALING POINTS

AC204330

SEALANT:

3M



 AAD PART NO.8672, 8679, 

8678, 8661,8663 OR EQUIVALENT

AB

FLUID:

GENUINE MITSUBISHI POWER 
STEERING FLUID

FLUID:

GENUINE MITSUBISHI POWER 
STEERING FLUID

FLUID:

GENUINE MITSUBISHI POWER 
STEERING FLUID

FLUID:

GENUINE MITSUBISHI POWER 
STEERING FLUID

FLUID:

GENUINE MITSUBISHI POWER 
STEERING FLUID

FLUID:

GENUINE MITSUBISHI 
POWER STEERING FLUID

GREASE: 

SILICONE GREASE

SEALANT: 

MITSUBISHI GENUINE PART NO. 

        MZ100116EX

SEALANT MARKED BY * SHOULD BE 
APPLIED AROUND THE ENTIRE EDGE OF
THE LARGER OUTER DIAMETER.

CAUTION

SEALANT MARKED BY * SHOULD 
BE APPLIED AROUND THE 
THREAD. ALSO ENSURE THAT 
THE SEALANT DOES NOT ENTER 
THE GEAR HOUSING.

BAND

BELLOWS

CAUTION

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

POWER STEERING

37A-34

DISASSEMBLY SERVICE POINTS

.

<<A>> RACK SUPPORT COVER REMOVAL
Using special tool MB991204, remove the rack support cover 
from the gear box.

.

<<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 and the rack.

.

ACX01142AB

MB991204

ACX01143 AB

ACX01144 AB