PURPOSE

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

BACKGROUND

The inside and outside surfaces of the Front Crossmembers 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

2008 – 2010 Lancer*

2009 - 2010 Lancer Sportback*

2008 -2013 Outlander*

2011 – 2016 Outlander Sport / RVR*

*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 Crossmember corrosion, but is not covered under this campaign (i.e., never registered in a salt belt state), contact your DPSM for further directions.

REQUIRED TOOLS, EQUIPMENT AND MATERIALS

1. Obtain necessary tools, equipment and materials.
2. Dealers that do not already have the Spray Gun, Regulator or Anti-Corrosion agents listed below, should order through their facing PDC.<

Inspect consistency of the Anti-Corrosion Agent (P/N: MZ341024EX) before use. The consistency should be smooth and creamy. If the consistency is chunky (like cottage cheese) do not use and discard the product.<

FLOW CHART

2. Review flow chart

INSPECTION PROCEDURE

3. Raise the vehicle on a lift.
4. Remove under cover clips and under cover.

5. Inspection by punch testing.
1. Prepare punch and hammer.

2. Put the punch on the points shown below and strike the punch 5 times with the hammer. The punching point is located approximately 20mm from the weld and outward approximately 10mm from the pipe on the left and right sides, as shown below.
3. If the Crossmember becomes perforated, please replace the Crossmember.

NOTE: Crossmember removed from vehicle for illustration purposes.

Wear safety glasses, respirator, and protective gloves when punching, removing rust and cleaning the Crossmember.

6. Clean the Crossmember and remove rust without removing the Crossmember from the vehicle.
1. Remove any dirt, mud and water from outside and inside of the Crossmember by using compressed air.
2. Remove loose rust and rust scales from the external surface of the Crossmember by using a scraper, chisel, or flathead screw driver.
3. Remove any remaining rust or dirt from the Crossmember by using a wire brush until the surface is smooth and clean.
4. Visually inspect the Crossmember during the rust removal process. If rust perforation is found, proceed to the Crossmember replacement.

NOTE: Crossmember removed from vehicle for illustration purposes only, in the photos below.

Application of anti-corrosion agent to the inside of the Crossmember

1. When using MZ341023EX spray gun, prepare for internal application, as follows:
1. Assemble the spray gun as illustrated below.
2. Set zero-point of discharge and air adjustment knobs.
3. Remove the cap of the container and fill the container with anti-corrosion agent. Attach the cap to the container.

4. Attach the air regulator and hose to the gun.
5. Adjust the discharge and the air adjustment knobs.
6. Adjust the compressor air pressure.

7. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is injected from nozzle.

Wear safety glasses when applying anti-corrosion agent.

2. When using the T99XXKXX01 spray gun with MZ321015 (used in Canada), prepare for internal application, as follows:
1. Assemble the spray gun as illustrated below.
2. Set zero-point of discharge and air supply adjustment knob.

3. Remove the cap on the gun container and fill with anti-corrosion agent.
4. Attach the air regulator and hose to the gun.
5. Adjust the discharge and fineness adjustment knob.

6. Adjust compressor air pressure.
7. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is injected from nozzle.

Wear safety glasses when applying anti-corrosion agent.

3. When using the T99XXKXX01 spray gun with MZ341024EX, prepare for internal application, as follows:
1. Assemble the spray gun as illustrated below.
2. Set zero-point of discharge and air supply adjustment knob.

3. Remove the cap on the gun container and fill with anti-corrosion agent.
4. Attach the air regulator and hose to the gun.
5. Adjust the discharge and fineness adjustment knob.

6. Adjust compressor air pressure.
7. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is injected from nozzle.

Wear safety glasses when applying anti-corrosion agent.

4. Anti-corrosion agent internal application should be completed without removing the Crossmember from the vehicle. According to the respective vehicle model, insert the nozzle into each hole as shown below.

When using the combination below:

Nozzle should be inserted into the 7 holes identified:

1. Spraying into the Hole A (RH) / A' (LH)

● Insert the nozzle through Hole A(A') in the direction shown below until it contacts the lower arm bracket (Insertion length: 240mm or 9.5 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the opening of the lower arm bracket.

● Apply MZ341024EX by engaging the trigger fully at the position demonstrated below and confirm the MZ341024EX leaks out of the opening of the lower arm bracket. Continue spraying while removing the nozzle, which should take 10 seconds.

2. Spraying into the Hole B (RH) / B' (LH)

● Insert the nozzle through Hole B (B') in the direction shown below until it contacts the lower arm bracket (Insertion length: 100mm or 4 inches). Confirm that the nozzle has been fully inserted in the correction direction by looking in the clip insertion hole.

● Apply MZ341024EX fully by engaging the trigger fully at this position for 10 seconds and continue spraying while removing the nozzle, which should take another 10 seconds.

3. Spraying into the Hole C (RH) / C' (LH) and D

● Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).

● Apply MZ341024EX fully by engaging the trigger fully and continue spraying while moving the nozzle in a circular motion for 10 seconds at each hole.

On Hole C and Hole D, insert nozzle until the nozzle is over weld nut. Make sure the anti-corrosion agent is not put on the inner surface of weld nut. Should anti-corrosion agent get on the inner surface of the weld nut; please remove by using a Universal Absorbent Pad.

When using the combination below:

Nozzle should be inserted into the 7 holes identified:

4. Spraying into the Hole A (RH) / A' (LH)

● Insert the nozzle through hole A(A') in the direction shown below until it contacts the lower arm bracket (Insertion length: 240mm or 9.5 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the opening of the lower arm bracket.

● Apply MZ321015 (used in Canada) by engaging the trigger fully at the position demonstrated below and confirm the MZ321015 leaks out of the opening of the lower arm bracket. Continue spraying while removing the nozzle, which should take 10 seconds.

5. Spraying into the Hole B (RH) / B' (LH)

● Insert the nozzle through Hole B (B') in the direction shown below until it contacts the lower arm bracket (Insertion length: 100mm or 4 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the clip insertion hole.

● Apply MZ321015 (used in Canada) by engaging the trigger fully at this position for 10 seconds and continue spraying while removing the nozzle, which should take another 10 seconds.

6. Spraying into the Hole C (RH) / C' (LH) and D

● Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).

● Apply MZ321015 (used in Canada) by engaging the trigger fully and continue spraying while moving the nozzle in a circular motion for 10 seconds at each hole.

On Hole C and Hole D, insert nozzle until the nozzle is over weld nut. Make sure the anti-corrosion agent is not put on the inner surface of weld nut. Should anti-corrosion agent get on the inner surface of the weld nut; please remove by using Universal Absorbent Pads.

When using the combination below:

Nozzle should be inserted into the 9 holes identified:

7. Spraying into the Hole A (RH) / A' (LH)

● Insert the nozzle through Hole A(A') in the direction shown below until it contacts the lower arm bracket (Insertion length: 180mm or 7 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the opening of the lower arm bracket.

● Apply MZ341024EX by engaging the trigger fully at the position demonstrated below and confirm the MZ341024EX leaks out of the opening of the lower arm bracket. Continue spraying while removing the nozzle, which should take 10 seconds.

8. Spraying into the Hole A (RH) / A' (LH)

● Insert the nozzle through Hole A(A') in the direction shown below until it contacts the lower arm bracket (Insertion length: 70mm or 2.75 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the opening of the lower arm bracket.

● Apply MZ341024EX by engaging the trigger fully at the position demonstrated below for 10 seconds and continue spraying while removing the nozzle, which should take 10 seconds.

9. Spraying into the Hole C (RH) / C' (LH) and D

● Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).

● Apply MZ321015 (used in Canada) by engaging the trigger fully and spray for 10 seconds at this position.

On Hole C and Hole D, insert nozzle until the nozzle is over weld nut. Make sure the anti-corrosion agent is not put on the inner surface of weld nut. Should anti-corrosion agent get on the inner surface of the weld nut; please remove by using Universal Absorbent Pads.

10. Spraying into the Hole E (RH) / E' (LH)

● Insert the nozzle through the Hole E (E') in the direction shown below (Insertion length: 180 mm or 7 inches).

● Apply MZ321015 (used in Canada) by engaging the trigger fully and spray for 10 seconds. Continue spraying while removing the nozzle, which should take 10 seconds.

When using the combination below:

Nozzle should be inserted into the 9 holes identified:

11. Spraying into the Hole A (RH) / A' (LH)

● Insert the nozzle through Hole A(A') in the direction shown below until it contacts the lower arm bracket (Insertion length: 180mm or 7 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the opening of the lower arm bracket.

● Apply MZ321015 (used in Canada) by engaging the trigger fully at the position demonstrated below and confirm the MZ321015 (used in Canada) leaks out of the opening of the lower arm bracket. Continue spraying while removing the nozzle, which should take 10 seconds.

12. Spraying into the Hole B (RH) / B' (LH)

● Insert the nozzle through Hole B (B') in the direction shown below until it contacts the lower arm bracket (Insertion length: 70mm or 2.75 inches). Confirm that the nozzle has been fully inserted in the correct direction by looking in the clip insertion hole.

● Apply MZ321015 (used in Canada) by engaging the trigger fully at this position for 10 seconds and continue spraying while removing the nozzle, which should take another 10 seconds.

13. Spraying into the Hole C (RH) / C' (LH) and D

● Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).

● Apply MZ321015 (used in Canada) by engaging the trigger fully and spray for 10 seconds at this position.

On Hole C and Hole D, insert nozzle until the nozzle is over weld nut. Make sure the anti-corrosion agent is not put on the inner surface of weld nut. Should anti-corrosion agent get on the inner surface of the weld nut; please remove by using Universal Absorbent Pads.

14. Spraying into the Hole E (RH) / E' (LH)

● Insert the nozzle through the Hole E (E') in the direction shown below (Insertion length: 180 mm or 7 inches).

● Apply MZ321015 (for Canada) by engaging the trigger fully and spray for 10 seconds. Continue spraying while removing the nozzle, which should take 10 seconds.

Application of anti-corrosion agent - MZ320800 - to the outside of the

Crossmember.

Wear safety glasses, respirator, and gloves when spraying MZ320800.

1. Masking:

• Mask rubber components such as suspension bushings, brake hoses, steering gear box boots/drive shaft boots, and exhaust pipe to prevent MZ320800 from coming into contact with these components.

2. MZ320800 external application:

• Without detaching the Crossmember from the vehicle, apply MZ320800 by positioning the nozzle 100 to 200 mm (or 4 to 8 inches) away from the Crossmember surface in the following order:

● Step 1 Front surface

● Step 2 Right surface

● Step 3 Rear surface

● Step 4 Left side surface

● Step 5 bottom surface

● Spray MZ320800 by moving the nozzle at a constant speed of 0.2m/second (or 8 inches/second). Spray it 2 to 3 times, repeatedly.

Wear safety glasses, respirator, and gloves when spraying MZ320800.

1. Step 1 - Front surface:

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

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

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

3. Step 3 - Rear surface / Step 5 bottom surface:

● Mask exhaust pipe.

PARTS INFORMATION

Use only the Genuine Mitsubishi Parts listed below:

NOTE: Additional spray gun or air regulators may be purchased at dealer's expense.

WARRANTY INFORMATION

Warranty / Recall Campaign Claim Information

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

Please follow the campaign instructions below.

Certain affected vehicles:

2008 – 2010 Lancer*
2009 - 2010 Lancer Sportback*
2008 - 2013 Outlander*
2011 – 2016 Outlander Sport / RVR*

NOTE: Always check the Superscreen to verify vehicle involvement.

A claim example for reference:

LABOR AND PARTS

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 - replace Crossmember. Do not apply anti-rust agent.<

Each can of the anti-rust agents is enough to complete 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.<

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.

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.

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