SR-20-003REV_2

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SUBJECT:
CROSSMEMBER CORROSION - SAFETY
RECALL CAMPAIGN
No:
SR-20-003REV_2
DATE:
August 2020
MODEL:
SEE BELOW
CIRCULATE TO:
[ X ] GENERAL MANAGER
[ X ] PARTS MANAGER
[ X ] TECHNICIAN
[ X ] SERVICE ADVISOR
[ X ] SERVICE MANAGER
[ X ] WARRANTY PROCESSOR
[ X ] SALES MANAGER
This bulletin supersedes SR-20-003REV_1, issued July 2020; changes include:
D
Added Warranty Information for instances where subframe may fail and cause additional
damage to unrelated parts. (Page 31)
Revisions are italicized and indicated by A.
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.
IMPORTANT
Affected new or used inventory vehicles must be repaired before the vehicle is delivered. Dealers
must check their inventory vehicles’ VINs on the Warranty Superscreen to verify whether the
vehicle is involved in this recall campaign. It is a violation of Federal law for a dealer to deliver a
new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered
by the notification under a sale or lease until the defect or noncompliance is remedied.
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.
Copyright 2020, Mitsubishi Motors North America, Inc.
The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi
Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).
Continued (4973)
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SR-20-003REV_2
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.
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!! IMPORTANT !!
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.
ANTI-CORROSION AGENT
SPRAY GUN PART #:
MZ341024EX ANTI-CORROSION AGENT
MZ321015 (Canada) ANTI-CORROSION AGENT
MZ341023EX
Reference Page 12
Reference Page 15
T99XXKXX01
Reference Page 17
Reference Page 22
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FLOW CHART
2. Review flow chart
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INSPECTION PROCEDURE
3.
Raise the vehicle on a lift.
4.
Remove under cover clips and under cover.
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5.
Inspection by punch testing.
a.
Prepare punch and hammer.
b. 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.
c.
If the Crossmember becomes perforated, please replace the Crossmember.
NOTE: Crossmember removed from vehicle for illustration purposes.
! CAUTION
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.
a.
Remove any dirt, mud and water from outside and inside of the Crossmember by using
compressed air.
b. Remove loose rust and rust scales from the external surface of the Crossmember by using
a scraper, chisel, or flathead screw driver.
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c.
Remove any remaining rust or dirt from the Crossmember by using a wire brush until the
surface is smooth and clean.
d. 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.
Before
Before
After
After
Application of anti-corrosion agent to the inside of the Crossmember
1.
When using MZ341023EX spray gun, prepare for internal application, as follows:
a.
Assemble the spray gun as illustrated below.
b. Set zero-point of discharge and air adjustment knobs.
c.
Remove the cap of the container and fill the container with anti-corrosion agent. Attach
the cap to the container.
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d. Attach the air regulator and hose to the gun.
e.
Adjust the discharge and the air adjustment knobs.
f.
Adjust the compressor air pressure.
g. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is
injected from nozzle.
! CAUTION
Wear safety glasses when applying anti-corrosion agent.
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2.
When using the T99XXKXX01 spray gun with MZ321015 (used in Canada), prepare for internal
application, as follows:
a. Assemble the spray gun as illustrated below.
b. Set zero-point of discharge and air supply adjustment knob.
c. Remove the cap on the gun container and fill with anti-corrosion agent.
d. Attach the air regulator and hose to the gun.
e. Adjust the discharge and fineness adjustment knob.
f. Adjust compressor air pressure.
g. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is
injected from nozzle.
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! CAUTION
3.
Wear safety glasses when applying anti-corrosion agent.
When using the T99XXKXX01 spray gun with MZ341024EX, prepare for internal application, as
follows:
a.
Assemble the spray gun as illustrated below.
b. Set zero-point of discharge and air supply adjustment knob.
c.
Remove the cap on the gun container and fill with anti-corrosion agent.
d. Attach the air regulator and hose to the gun.
e.
Adjust the discharge and fineness adjustment knob.
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f.
Adjust compressor air pressure.
g. Test the spray gun by fully engaging the gun trigger to confirm anti-corrosion agent is
injected from nozzle.
! CAUTION
4.
Wear safety glasses when applying anti-corrosion agent.
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.
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08-13MY Outlander (L4 Engine), 08-10MY Lancer / 11-16MY Outlander Sport / RVR
Anti-Corrosion
Agent
Spray Gun
MZ341024EX
MZ321015 (used in Canada)
MZ341023EX
MZ341023EX
Discharge adjustment
½ turn (in summer)
knob
to 4 turns (in winter)
MZ321015 (used in Canada)
MZ341024EX
T99XXKXX01
-
Air supply adjustment
1 turn
knob
Spray Gun
Discharge adjustment
Setting
knob
4 and ½ turns
3 turns
1 turn
2 and ¼ turns
Fineness adjustment
knob
Air pressure
51 PSI (350 Kpa) in summer - to - 71 PSI (490 Kpa) in winter
Insert length of hose
240
180
(mm)
Hole A, A'
Spraying time (s)
Until Anti-Corrosion agent leaks from the opening of the lower arm bracket
Spraying time during
10 seconds
removal
Insert length of hose
100 mm
70 mm
(mm)
Hole B, B'
Spraying time (s)
10 seconds
Spraying time during
10 seconds
removal
Insert length of hose
25 mm
Hole C, C'
(mm)
Spraying time (s)
10 seconds
Insert length of hose
25 mm
Hole D
(mm)
Spraying time (s)
10 seconds
Insert length of hose
180 mm
(mm)
Hole E, E'
Spraying time (s)
-
10 seconds
Spraying time during
10 seconds
removal
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When using the combination below:
Anti-Corrosion Agent
Spray Gun
MZ341024EX
MZ321015 (used in
Canada)
MZ341023EX
T99XXKXX01
X
-
X
-
Nozzle should be inserted into the 7 holes identified:
a.
Spraying into the Hole A (RH) / A' (LH)
D
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.
D
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.
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b. Spraying into the Hole B (RH) / B' (LH)
D
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.
D
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.
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c.
Spraying into the Hole C (RH) / C' (LH) and D
D
Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).
D
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.
! CAUTION
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.
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When using the combination below:
Anti-Corrosion Agent
Spray Gun
MZ341024EX
MZ321015 (used in
Canada)
MZ341023EX
T99XXKXX01
-
X
X
-
Nozzle should be inserted into the 7 holes identified:
d. Spraying into the Hole A (RH) / A' (LH)
D
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.
D
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.
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e.
f.
Spraying into the Hole B (RH) / B' (LH)
D
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.
D
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.
Spraying into the Hole C (RH) / C' (LH) and D
D
Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).
D
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.
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! CAUTION
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:
Anti-Corrosion Agent
Spray Gun
MZ341024EX
MZ321015 (used in
Canada)
MZ341023EX
T99XXKXX01
X
-
-
X
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Nozzle should be inserted into the 9 holes identified:
g. Spraying into the Hole A (RH) / A' (LH)
D
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.
D
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.
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h. Spraying into the Hole A (RH) / A' (LH)
D
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.
D
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.
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i.
Spraying into the Hole C (RH) / C' (LH) and D
D
Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).
D
Apply MZ321015 (used in Canada) by engaging the trigger fully and spray for 10 seconds
at this position.
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! CAUTION
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.
j.
Spraying into the Hole E (RH) / E' (LH)
D
Insert the nozzle through the Hole E (E') in the direction shown below (Insertion length:
180 mm or 7 inches).
D
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.
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When using the combination below:
Anti-Corrosion Agent
Spray Gun
MZ341024EX
MZ321015 (used in
Canada)
MZ341023EX
T99XXKXX01
-
X
-
X
Nozzle should be inserted into the 9 holes identified:
k.
Spraying into the Hole A (RH) / A' (LH)
D
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.
D
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.
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l.
Spraying into the Hole B (RH) / B' (LH)
D
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.
D
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.
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m. Spraying into the Hole C (RH) / C' (LH) and D
D
Insert the nozzle through the Hole C (C') or D upwards (Insertion length: 25 mm or 1 inch).
D
Apply MZ321015 (used in Canada) by engaging the trigger fully and spray for 10 seconds
at this position.
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! CAUTION
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.
n. Spraying into the Hole E (RH) / E' (LH)
D
Insert the nozzle through the Hole E (E') in the direction shown below (Insertion length:
180 mm or 7 inches).
D
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.
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Application of anti-corrosion agent - MZ320800 - to the outside of the
Crossmember.
! CAUTION
1.
D
2.
Wear safety glasses, respirator, and gloves when spraying MZ320800.
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.
MZ320800 external application:
D
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:
D
Step 1 Front surface
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D
Step 2 Right surface
D
Step 3 Rear surface
D
Step 4 Left side surface
D
Step 5 bottom surface
D
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.
! CAUTION
a.
Wear safety glasses, respirator, and gloves when spraying MZ320800.
Step 1 - Front surface:
D
Mask steering gear box boots, drive shaft boots and exhaust pipe.
b. Step 2 - Right side surface / Step 4 - Left side surface:
D
Mask suspension bushings, steering gear box boots, drive shaft boots, and brake hoses.
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c.
Step 3 - Rear surface / Step 5 bottom surface:
D
Mask exhaust pipe.
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PARTS INFORMATION
Use only the Genuine Mitsubishi Parts listed below:
Part Number
Part Description
Quantity/Vehicle
Comments
MZ341024EX or
Anti-Corrosion Agent
(Use with spray gun)
5 vehicles per bottle
For inside of the
Crossmember
MZ320800
Anti-Corrosion Agent
(Aerosol)
5 vehicles per can
For outside of the
Crossmember
MW400273
Crossmember
1
For applicable
replacement
MZ321015 (in Canada)
NOTE: Additional spray gun or air regulators may be purchased at dealer's expense.
WARRANTY INFORMATION
D
For instances where the sub-frame fails and causes additional damage to unrelated parts; PRC
submission is required. Dealers should submit photos and make direct contact to the Warranty
Hotline for resolution.A
Vehicles
2008-2010 Lancer, 2009-2010 Lancer
Sportback, 2008-2013 Outlander,
2011-2012 Outlander Sport / RVR &
2016 Outlander Sport / RVR
2013 Outlander Sport / RVR
2014-2015 Outlander Sport / RVR
Campaign
Operation
Labor
Time
(hrs)
C2003R01
1.0
Inspection & Application of Anti-Rust
Agents (Lancer, Lancer Sportback)
C2003R02
0.9
Inspection & Application of Anti-Rust
Agents (Outlander, Outlander Sport/
RVR)
C2003R03
3.3
Inspection & Replacement of Cross­
member (Lancer, Lancer Sportback,
Outlander)
C2003R04
2.5
Inspection & Replacement of Cross­
member (Outlander Sport/RVR)
C2003X01
0.9
Inspection & Application of Anti-Rust
Agents (2013 Outlander Sport/RVR)
C2003X02
2.5
Inspection & Replacement of Cross­
member (2013 Outlander Sport/RVR)
C2003Z01
0.9
Inspection & Application of Anti-Rust
Agents
C2003Z02
2.5
Inspection & Replacement of Cross­
member
Repair Description
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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
2009
2008
2011
– 2010 Lancer*
- 2010 Lancer Sportback*
- 2013 Outlander*
– 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.
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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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