Mitsubishi Endeavor 2004-06

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. On vehicles equipped with a supplemental restraint system (SRS), turn the front wheel to the straight ahead position and remove the ignition key to prevent the steering wheel from turning.
  4.  


NOTE
Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clockspring and render SRS system inoperative.

  1. Drain the power steering system.
  2.  
  3. Disconnect the negative battery cable. Insulate the cable end with high-quality electrical tape or similar non-conductive wrapping Wait at least 1 minute before proceeding.
  4.  
  5. Remove the steering wheel, as follows:
    1. Pry the cover from the steering wheel.
    2.  
    3. Detach the connector, and retainers, as necessary then remove the air bag module assembly
    4.  
    5. Remove the steering wheel nut, then use a puller to remove the steering wheel.
    6.  
    7. Detach the sub-harness.
    8.  

  6.  
  7. Remove the clock spring and put aside in a safe place.
  8.  
  9. Remove or disconnect the following:

    Front scuff plate and cowl side trim
     
    Front floor left side console cover
     
    Front floor carpet
     
    Stabilizer link and lower control arm assembly
     
    Center member
     
    Shaft pad
     
    Steering column shaft assembly and steering gear connecting bolt
     
    Tie rod end from the steering knuckle, using a suitable puller
     
    Fluid return hose and return tube. Plug the hoses. Remove and discard the O-ring.
     
    Pressure hose connection and hose gasket
     
    Rear roll stopper connecting bolt
     
    Self-locking nut
     
    Front axle crossmember stay
     
    Plate stopper
     

  10.  
  11. Use a transaxle jack to support the crossmember, then remove the crossmember mounting nuts and bolts. Lower the crossmember with the rear roll stopper, stabilizer bar, return tube and steering gear.
  12.  
  13. Remove the following from the crossmember.

    Rear roll stopper
     
    Front axle No. 1 crossemember
     
    Power steering gear bracket
     
    Heat protector
     
    Steering gear mounting gear side bracket
     
    Steering gear
     
    Steering gear joint cover
     

  14.  


    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear


To install:

  1. Installation is the reverse of the removal procedure. Refer to the illustration for tightening specifications.
  2.  
  3. Refill the reservoir and bleed the system.
  4.  
  5. Perform a front end alignment.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Position the front wheel in the straight ahead position and remove the ignition key to prevent the steering wheel from turning.
    NOTE
    Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clock spring and render SRS system inoperative.

  4.  
  5. Drain the power steering system.
  6.  
  7. Disconnect the negative battery cable. Insulate the cable end with high-quality electrical tape or similar non-conductive wrapping Wait at least 1 minute before proceeding.
  8.  
  9. Remove the steering wheel, as follows:
    1. Pry the cover from the steering wheel.
    2.  
    3. Detach the connector, and retainers, as necessary then remove the air bag module assembly
    4.  
    5. Remove the steering wheel nut, and then use a puller to remove the steering wheel.
    6.  
    7. Detach the sub-harness.
    8.  

  10.  
  11. Remove the clock spring and put aside in a safe place.
  12.  
  13. Remove or disconnect the following:

    Front scuff plate and cowl side trim
     
    Front floor left side console cover
     
    Front floor carpet
     
    Stabilizer link and lower control arm assembly
     
    Center member
     
    Shaft pad
     
    Steering column shaft assembly and steering gear connecting bolt
     
    Tie rod end from the steering knuckle, using a suitable puller
     
    Fluid return hose and return tube. Plug the hoses. Remove and discard the O-ring.
     
    Pressure hose connection and hose gasket
     
    Rear roll stopper connecting bolt
     
    Self-locking nut
     
    Front axle crossmember stay
     
    Plate stopper
     

  14.  
  15. Use a transaxle jack to support the crossmember, then remove the crossmember mounting nuts and bolts. Lower the crossmember with the rear roll stopper, stabilizer bar, return tube and steering gear.
  16.  
  17. Remove the following from the crossmember.

    Rear roll stopper
     
    Front axle No. 1 crossmember
     
    Power steering gear bracket
     
    Heat protector
     
    Steering gear mounting gear side bracket
     
    Steering gear
     
    Steering gear joint cover

    Click image to see an enlarged view

    Fig. Power steering gear and related components

     

  18.  

To install:

  1. Align the steering joint cover notch with the steering gear lug. Install the steering joint cover to the steering gear.
  2.  
  3. From inside the vehicle, pull tab -A- and then tab -B- to secure the three clips to the body panel.
    NOTE
    When securing the joint cover to the body panel, be careful that the cover seal lip does not move backwards.

  4.  
  5. After installing the joint cover, check that the joint cover rubber is not disengaged from the retainer. If there is any doubt, release the clips from the body and start the procedure again.

    Click image to see an enlarged view

    Fig. Steering joint cover notch alignment



    Click image to see an enlarged view

    Fig. Steering joint cover tab -A- and tab -B- location



    Click image to see an enlarged view

    Fig. Steering gear bracket installation points

  6.  
  7. Tighten the power steering gear bracket bolts in the order shown in the illustration.
  8.  
  9. Continue the installation in the reverse order of the removal procedure.
    NOTE
    When installing the clock spring, ensure that the mating marks are properly aligned. If not the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver.



    Click image to see an enlarged view

    Fig. Air bag clock spring alignment

  10.  
  11. To align the mating marks of the clock spring, turn the clock spring counterclockwise fully. Then turn it back approximately 3 3/4 turns counterclockwise to align the mating marks.
  12.  
  13. Turn the front wheels to the straight ahead position. Then install the clock spring to the column switch.
    NOTE
    If the vehicle is equipped with Active Skid Control (ASC), ensure that the steering wheel sensor-s mating marks are properly aligned. If not, the steering wheel sensor could be damaged.



    Click image to see an enlarged view

    Fig. Active Skid Control (ASC) sensor alignment

  14.  
  15. To align the mating marks, if the vehicle is equipped with Active Skid Control (ASC), turn the steering wheel sensor clockwise fully. Then turn it back approximately 2 3/4 turns counterclockwise to align the mating marks. Align the mating marks on the clock spring and the steering wheel sensor, and install the steering wheel sensor to the column switch assembly. Connect the steering wheel sensor connector.
  16.  
  17. Connect the negative battery cable. On 2005-2006 vehicles, turn the ignition ON and then OFF , and keep it off for at least ten seconds.
  18.  
  19. Refill the reservoir and bleed the system.
  20.  
  21. Check and adjust the front end alignment, as required.
  22.  

 
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