Mitsubishi Montero Sport (2004+). Manual - part 828

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

STEERING

37A-35

ASSEMBLY

M1372004300076

Required Special Tools:

• MB990228 or MB991006: Preload Socket

• MB990926: Installer Adapter

• MB990938: Bar (Snap-in type)

AC004351

GEAR BOX SEAL KIT

CROSS SHAFT
PLATE SET

CROSS SHAFT
SEAL KIT

9

4

2

3

5 6

8

10

9

8

2

3

13

16

14

9

8

10

11

12

7

15

5

6

4

1

2

17

3

18

37 N·m
27 ft-lb

54 - 64 N·m
40 - 47 ft-lb

56 - 64 N·m
41 - 47 ft-lb

147 - 167 N·m
108 - 123 ft-lb

AB

DISASSEMBLY STEPS

1.

GEAR MOUNTING RUBBER

2.

Y-PACKING

>>A<<

3.

OIL SEAL

4.

O-RING

5.

O-RING

6.

SEAL RING

7.

MAINSHAFT AND VALVE ASSEMBLY

8.

Y-PACKING

9.

O-RING

>>B<<

10.

ADJUSTING PLATE

>>B<<

11.

ADJUSTING BOLT

>>C<<

12.

CROSS-SHAFT

>>C<<

13.

ADJUSTING BOLT JAM NUT

14.

SIDE COVER

>>D<<

15.

SIDE COVER AND CROSS-SHAFT 
ASSEMBLY

16.

BOLT

>>E<<

•

MAINSHAFT TOTAL BREAKAWAY 
TORQUE ADJUSTMENT

>>F<<

17.

PITMAN ARM

18.

JAM NUT

DISASSEMBLY STEPS (Continued)

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

STEERING

37A-36

LUBRICATION AND SEALING POINTS

AC103637

SEALANT: 3M™ AAD PART NO.8672, 
8679, 8678, 8661, 8663 OR EQUIVALENT

AC

SPECIFIED GREASE: MULTIPURPOSE
GREASE SAE J310, NLGI No.2 OR 
EQUIVALENT

FLUID: GENUINE 

MITSUBISHI POWER 

STEERING FLUID

FLUID: GENUINE MITSUBISHI 
POWER STEERING FLUID

FLUID: GENUINE MITSUBISHI POWER 
STEERING FLUID

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

STEERING

37A-37

ASSEMBLY SERVICE POINTS

.

>>A<< OIL SEAL INSTALLATION
Apply a coating of GENUINE MITSUBISHI POWER STEER-
ING FLUID to the outside of the oil seal. Using special tools 
MB991199 and MB991197, press the oil seal into the rack 
housing.

.

>>B<< ADJUSTING PLATE/ADJUSTING BOLT 
INSTALLATION
1. Install the adjusting plate so that the beveled part is facing 

downward.

2. Use a feeler gage to measure the clearance between the 

adjusting bolt and the cross-shaft.

Standard value: 0.05 mm (0.02 inch)

3. If the clearance exceeds the standard value, replace with a 

suitable adjusting plate.

.

>>C<< CROSS-SHAFT/ADJUSTING BOLT JAM NUT 
INSTALLATION
Install the cross-shaft to the side cover, and then temporarily 
tighten the adjusting bolt jam nut.

.

AC004352

OIL SEAL

MB990938

MB990926

AB

AC004356

ADJUSTING 
BOLT

ADJUST-
ING 
PLATE

AB

POWER STEERING GEAR BOX ASSEMBLY

TSB Revision

STEERING

37A-38

>>D<< SIDE COVER AND CROSS-SHAFT ASSEMBLY 
INSTALLATION

CAUTION

Do not rotate the side cover during installation. Take care 
not to damage the cross-shaft oil seal.
Install the side cover assembly (with the cross-shaft) to the 
gear box.
NOTE: Apply GENUINE MITSUBISHI POWER STEERING 
FLUID to the teeth and shaft areas of the rack piston, and apply 
multipurpose grease to the oil seal lip.

.

>>E<< MAINSHAFT TOTAL BREAKAWAY TORQUE 
ADJUSTMENT

CAUTION

Adjust by turning the adjusting bolt so that the breakaway 
torque at the center position of the rack piston is approxi-
mately 0.2 N

⋅m (1.8 in-lb) higher than the values at the both 

ends of the rack piston.
1. While turning the adjusting bolt, measure the mainshaft total 

breakaway torque by using special tool MB990228 or 
MB991006.

Standard value: 0.69 

− 1.28 N⋅m (6 -12 in-lb)

2. Tighten the adjusting bolt jam nut to the specified torque.

Tightening torque: 37 N

⋅m (27 ft-lb)

.

AC004354AB

Y-PACKING

OIL SEAL

AC004355

MB990228 OR
MB991006

AB