Parts for your 1991 Mitsubishi Pajero-Rack boots

1991 Mitsubishi Pajero rack boots: are they even a thing?

Short answer: rack boots aren’t used on a 1991 Mitsubishi Pajero. That model runs a recirculating-ball steering box rather than a rack-and-pinion setup, so there’s no steering rack and therefore no rack boots (also called rack gaiters) to service. Technical references including the Mitsubishi Pajero/Montero Workshop Manual (1991, Group 37 – Steering) and the Mitsubishi ASA electronic parts catalogue for the L040/V20 series list a ball-nut steering gear with a pitman arm, centre/drag link, idler arm and tie-rod assemblies, but no rack or bellows-type rack boots. General service guides like the Haynes/Gregory’s manuals for 1983–1997 Pajero/Montero echo the same layout and components.

Why did Mitsubishi go this way? On heavy-duty 4x4s of the era, a recirculating-ball steering box was preferred for durability, impact resistance off-road and packaging with a ladder chassis. It copes well with big tyres and rough tracks. Rack-and-pinion units, which use rubber bellows (rack boots) to protect the rack from dust and grit, are more common on lighter passenger vehicles and later SUVs.

If someone’s shopping for “rack boots” for a 1991 Pajero, they’re looking for the wrong part. The smart play is to focus on the bits this steering system actually uses:

• Tie-rod end and drag-link dust boots – replace if split or weeping grease.
• Idler arm bushes/bearing – check for play and perishing.
• Pitman arm and sector shaft seals – inspect for power steering fluid leaks at the box.
• Steering damper – look for oil seepage or reduced damping.

As part of regular servicing, a workshop should put the Pajero on stands and check free play at the wheel, then inspect all steering joints and boots, adjust steering box lash if specified, and ensure the power steering system is leak-free. After any steering work, a proper wheel alignment will keep tyre wear tidy and steering feel consistent. For anyone doing remote touring around Aus or NZ, throwing a spare idler arm kit and a couple of tie-rod ends in the kit isn’t a bad shout.

• Does a 1991 Mitsubishi Pajero have rack boots?
  No. It uses a recirculating-ball steering box, not a rack-and-pinion. That means there are no rack gaiters/boots to replace. The factory workshop manual for 1991 specifies a ball-nut steering gear with pitman and idler arms, confirming no steering rack is fitted.
• What should be inspected instead of rack boots?
  Check tie-rod end and drag-link dust boots, the idler arm bushes/bearing, pitman arm and steering box seals, and the steering damper. Any split boot or fluid leak should be sorted promptly to prevent accelerated wear.
• Can a 1991 Pajero be converted to rack-and-pinion?
  It’s not a practical or common conversion. The chassis, suspension geometry and steering layout are designed around a steering box. Converting would require significant fabrication, certification and parts sourcing, which typically outweighs any benefit for an off-road-oriented Pajero.