Mitsubishi Outlander 2003-06

Removal & Installation

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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. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the power steering system.
  4.  
  5. Remove or disconnect the following:

    Battery negative cable. Insulate the cable end with high-quality electrical tape or similar non-conductive wrapping Wait at least 1 minute before proceeding.
     
    Heated Oxygen (HO2) sensor and remove the front exhaust pipe
     

  6.  
  7. Properly support the engine.

    Roll stopper mounting bolts and the 4 center member installation bolts. Remove the center member.
     
    Center member
     

  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, 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 the stabilizer link and lower control arm assembly.
  14.  
  15. Remove or disconnect the following:

    Shaft cover
     
    Steering column shaft assembly and steering gear
     
    Tie rod end from the steering knuckle, using a suitable puller
     
    Rear roll stopper bolt
     
    Fluid return hose and return tube. Plug the hoses. Remove and discard the O-ring.
     
    Pressure hose connection and hose gasket
     

  16.  
  17. 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.
  18.  
  19. Remove the following from the crossmember.

    Rear roll stopper
     
    Joint cover grommet
     
    Steering extension
     
    Return tube
     
    Crossmember
     
    Steering gear
     

  20.  


    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear


To install:

  1. Install or connect the following:

    Steering gear into the vehicle. Tighten the bolts to 45-59 ft. lbs. (60-80 Nm)
     
    Crossmember to the vehicle with the return tube, joint cover grommet, steering extension and rear roll stopper. Tighten the crossmember assembly bolts to 30-44 ft. lbs. (39-59 Nm) and the nuts to 116-130 ft. lbs. (158-176 Nm).
     
    Pressure hose with a new gasket. Tighten the bolt to 37-47 ft. lbs. (50-64 Nm).
     
    Fluid return tube with a new O-ring
     
    Return hose connection
     
    Rear roll stopper connecting bolt
     
    Tie rod end to the steering knuckle
     
    Steering gear connecting bolt and steering column shaft assembly
     
    Shaft cover
     
    Stabilizer and lower control arm assembly
     
    Center member and roll stopper mounting bolts
     
    Front exhaust pipe and HO2 sensor, if removed
     
    Clock spring
     
    Steering wheel. Tighten the nut to 24-36 ft. lbs. (33-49 Nm).
     
    Attach the sub-harness
     
    Air bag module, retainer and electrical connector
     
    Cover to the steering wheel
     
    Wheels and connect the negative battery cable
     

  2.  
  3. Refill the reservoir and bleed the system.
  4.  
  5. Perform a front end alignment.
  6.  

 
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