Parts for your 2005 Mitsubishi Pajero-Rack boots

2005 Mitsubishi Pajero rack-boots: purpose, fitment and servicing advice

Yes, rack-boots are fitted to the 2005 Mitsubishi Pajero. Technical references including the Mitsubishi Pajero/Montero NM–NP Workshop Manual (Group 37A – Steering, 2000–2006) and the Mitsubishi ASA/CAPS electronic parts catalogue specify a power-assisted rack-and-pinion steering gear with bellows-type rack boots on both sides. Aftermarket catalogues commonly used in AU/NZ workshops also list direct-fit steering rack boots for 11/2000–2006 Pajero models, which backs up the factory documentation.

On this Pajero, the rack-boots (also called bellows boots) do a deceptively important job: they seal the inner tie rods and the ends of the steering rack from grit, water and mud while letting the rack slide freely. That keeps the grease where it belongs, stops corrosion pitting on the rack bar, and protects the inner tie rod joints. A split or perished boot lets in sand and moisture—bad news for anyone who tours beaches, river crossings or corrugated outback tracks—and can quickly turn into inner tie-rod play, notchy steering and pricey rack damage. It’s also a common WOF/RWC fail item if torn or leaking.

Practical care is simple. Inspect the boots at each service (10,000–15,000 km), and more often if the Pajero sees off-road work. Look for cracks, oil inside the boot (which can indicate a leaking rack seal), loose clamps, or grease flung onto the crossmember. If one boot is gone, replacing them as a pair is a smart move.

Replacement on the 2005 Pajero is straightforward for a competent DIYer: mark the tie-rod end position or measure toe so alignment stays close, disconnect the outer tie-rod end, remove the old boot and clamps, check the inner tie-rod for play, then slide the new boot on without twisting it. Use proper stainless or ear-type clamps rather than cable ties. Many Pajero racks use a breather/equaliser to balance pressure between the boots—make sure that tube is connected if fitted. Don’t pack the boot with grease unless the workshop manual specifies, it’s a dust boot, not a grease reservoir. Once done, a wheel alignment is recommended, especially if the outer tie-rod locknut was moved.

• Service tip: after water crossings, recheck the boots for fresh splits.
• If fluid is found inside a boot, plan for rack seal repair or replacement.
• Use quality EPDM boots, cheap rubber hardens quickly in Aussie/Kiwi summers.

Popular questions about 2005 Mitsubishi Pajero rack-boots

How often should the rack-boots be replaced on a 2005 Pajero?
There’s no fixed interval—replace on condition. Inspect every service or after harsh off-road use. If there are cracks, splits, loose clamps or contamination inside, swap them out right away.

Is it safe to drive with a torn rack-boot?
Short-term local trips may be possible, but it’s risky. A torn boot lets in grit and water that can chew out the inner tie rod and rack seals quickly, and it can cause a WOF/RWC failure. Best to repair promptly.

Do I need a wheel alignment after replacing rack-boots?
It’s wise, especially if the outer tie rod was removed or the locknut moved. Even careful reassembly can nudge toe out of spec, so getting an alignment will keep tyre wear and steering feel spot on.