PURPOSE

This bulletin provides directions for inspection and repair of affected vehicles' cross members.

BACKGROUND

The inside and outside surfaces of the front cross members used on certain vehicles, if exposed long term to snow melt water and anti-freezing agents, may corrode due to insufficient performance of the rust protection. Should significant corrosion occur over time, a lower control arm could eventually become detached resulting in loss of vehicle control and a potential collision.

AFFECTED VEHICLES

2002-2007 Lancer*, Lancer Wagon*, Lancer Evolution*

2003-2006 Outlander*

2007-2013 V6 Outlander*

*Currently or ever registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin, and Washington D.C.

NOTE: If you encounter a vehicle which has excessive cross member corrosion, but is not covered under this campaign (i.e., never registered in a salt belt state), contact your DPSM for further directions.

REQUIRED EQUIPMENT

FLOW CHART

*Perforation means a hole or a series of holes.

INSPECTION PROCEDURE

1. Raise the vehicle.
2. Remove under cover clips and under cover.

Wear safety glasses, respirator, and gloves when cleaning the cross member.

3. Clean the cross member and remove rust without removing the cross member from the vehicle.
1. Use compressed air to blow off any dirt, mud, or water from outside and inside of the cross member. If necessary, pressure spray stubborn mud or debris and dry thoroughly.
2. Remove loose rust and rust scales from the external surface of the cross member by using a scraper, chisel, or flat-head screw driver.
3. Use compressed air to blow off any remaining rust or dirt debris.
4. If rust perforation is found, proceed to the cross member replacement and application of anti-corrosion agent to both inside and outside of the replacement cross member. If no perforation is found, proceed to Step 4.

NOTE: Cross member removed from vehicle for illustration purposes.

4. Perform the punch test.
1. Prepare punch and hammer.

2. Tie the punch and hammer with a string so that they are approximately 4 in. apart.
3. Place the punch on the points shown below and strike the punch (5) times with the hammer. If the cross member becomes perforated, proceed to cross member replacement and application of anti-corrosion agent to both inside and outside of the replacement cross member.

NOTE: Cross member removed from vehicle for illustration purposes.

Application of anti-corrosion agent - NOX-RUST 712AM - to the inside of the cross member.

1. Prepare the spray gun for NOX-RUST 712AM (“NOX-RUST”) internal application.
1. Assemble the spray gun as illustrated:

2. Set zero-point of discharge and air adjustment knobs.
3. Remove the cap of the container and fill the container with NOX-RUST.
4. Reattach cap.
5. Attach the air regulator and hose to the gun.
6. Adjust the discharge and the air adjustment knobs.

NOTE: “Summer” is ambient temperature of 86 Degrees Fahrenheit (> 30 Degrees Celsius) or higher.
“Winter” is ambient temperature of 50 Degrees Fahrenheit (< 10 Degrees Celsius) or lower.

7. Test the spray gun by fully pulling on the trigger to confirm that the NOX-RUST is sprayed.

2007-2013 V6 Outlander

Wear safety glasses, respirator, and gloves when spraying NOX-RUST.

1. Insert the nozzle through hole A in the direction shown below until it contacts the lower arm bracket. Confirm that the nozzle has been fully inserted by looking through the clip insertion hole.

Spray NOX-RUST with full trigger pull for 5 seconds, then continue spraying while removing the nozzle. It should take between 3-5 seconds to fully remove the nozzle. NOTE: Ensure that the dashed oval area is fully coated.

3. Repeat for hole AA.
4. Insert the nozzle through hole B in the direction shown below until it contacts the lower arm bracket. (Insertion length: 9.5 in.) Confirm that the nozzle has been fully inserted by looking through the lower arm bracket opening.

Spray NOX-RUST with full trigger pull until NOX-RUST begins to leak out of the lower arm bracket opening, then continue spraying while removing the nozzle. It should take about 5 seconds to fully remove the nozzle. NOTE: Ensure that the dashed oval area is fully coated.

	Example: Lower arm bracket opening.
	Example: NOX-RUST leakage from cross member.

6. Repeat for hole BB.

Insert applicator nozzle approximately 1 in. into hole C and spray with full trigger pull while moving the applicator nozzle in a circular motion for 10 seconds, to ensure proper, even coverage. Repeat for holes CC and D.

2003-2006 Outlander / 2002-2007 Lancer

3. Insert the nozzle approximately 10 in. into hole A, as illustrated below, until it reaches the top of the body bracket. Spray NOX-RUST with full trigger pull for 5 seconds, then continue to spray while removing the nozzle. It should take approximately 5 seconds to remove the nozzle.
4. Repeat for hole AA.

Insert applicator nozzle approximately 1 in. into hole B and spray with full trigger pull while moving the applicator nozzle in a circular motion for 10 seconds, to ensure proper, even coverage. Repeat for holes BB, C, and CC.

CLEANING THE SPRAY GUN

With the discharge adjustment knob fully closed, spray air to eject traces of remaining wax in the hose and nozzle. If the spray gun will not be used for more than one week, fill the container with kerosene and spray to clean out the gun and associated spraying components.

Application of anti-corrosion agent - THREE RUSTER TB6154D - to the outside of the cross member.

Wear safety glasses, respirator, and gloves when spraying THREE RUSTER.

1. Mask rubber components such as suspension bushings, brake hoses, steering gear box boots and drive shaft boots, and exhaust pipe to to prevent THREE RUSTER TB6154D (“THREE RUSTER”) from coming into contact with these components.

1. Step 1: Front surface.

NOTE: Mask steering gear box boots, drive shaft boots and exhaust pipe.

2. Step 2 / Step 4: Right side surface / Left side surface.

NOTE: Mask steering gear box boots, suspension bushings, drive shaft boots and brake hoses.

3. Step 3 / Step 5: Rear surface / Bottom surface.

NOTE: Mask exhaust pipe.

2. Hold the spray nozzle approximately 4 to 8 in. away from the cross member surface and apply THREE RUSTER in the illustrated order. Move the spray at a rate of 8 in./sec. Repeat, if necessary, to ensure proper coverage of THREE RUSTER.

PARTS INFORMATION

Use only the Genuine Mitsubishi Parts listed below.

Anti-corrosion agent application:

NOTE: Dealers will be charged for the spray gun and air regulator on their parts statement. Dealers will be reimbursed, by the end of August, for the initial spray gun and air regulator shipment on a Warranty Claim created by MMNA. No dealer action is required for this reimbursement. Additional spray gun or air regulators can be purchased at dealer's expense.

Cross member and related parts:

NOTE: FED： Federal specification (excludes California); CAL： California specification

WARRANTY INFORMATION

Warranty / Recall Campaign Claim Information

Enter all claims as claim type ‘C’ – Recall/Campaign Claims

Please follow these campaign instructions. A claim example is provided below.

Certain-

2002-2007 MY Lancer, Lancer Wagon, Lancer Evolution

2003-2006 MY Outlander

2007-2013 MY Outlander (V6 only)

NOTE: Always check the Superscreen to verify vehicle involvement.

Required Operation to be performed Operation Lbr Time

1. All Involved:

Inspect for corrosion = OK Apply anti-rust agents C1609R01 0.9 hrs.

2. All (except 2007-13 Outlander V6):

Inspect for corrosion = NG Replace cross member & apply anti-rust agents C1609R02 3.2 hrs.

3. Only 2003-2007 Outlander with a V6

Inspect for corrosion = NG Replace cross member & apply anti-rust agents C1609R03 3.4 hrs.

LABOR AND PARTS

Labor:

There are only 2 possible repair scenarios for this campaign.

Scenario 1
Inspect = OK - then still must apply the 2 anti-rust agents only.

Scenario 2
Inspect = applicable corrosion - then replace cross member and specified related specified parts and apply the 2 anti-rust agents.

Parts:

Both scenarios require the application of the 2 anti-rust agents.

Only Scenario 2, requires the replacement of the cross member and specified related parts.

Each can of the anti-rust agents is enough to do 5 vehicles. Thus, the dealer net price for each of the materials is priced at dealer net divided by 5 and will be reflected automatically when entering the parts costs on the related recall campaign claim. Dealers will receive markup based on the per vehicle material prices.

RENTAL CARS:

If there is a need to provide the owner with a rental car or to claim return freight charges, claim the applicable charges in this section of the claim on the lower portion of the labor entry screen.

REPLACED PARTS:

Replaced parts must be held for at least 10 days beyond the recall claim payment date unless requested to be returned to MMNA. Return requested parts as you would any return requested warranty replaced part.

Copyright 2016, Mitsubishi Motors North America, Inc.