SR-20-003REV_2 Service Bulletin/Repair Instructions

Page 1 of 35
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)
Page 2 of 35

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.
Page 3 of 35

SR-20-003REV_2
!! 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
Page 4 of 35

SR-20-003REV_2
FLOW CHART

2. Review flow chart
Page 5 of 35

SR-20-003REV_2
INSPECTION PROCEDURE

3.
Raise the vehicle on a lift.
4.
Remove under cover clips and under cover.
Page 6 of 35

SR-20-003REV_2
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.
Page 7 of 35

SR-20-003REV_2
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.
Page 8 of 35

SR-20-003REV_2
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.
Page 9 of 35

SR-20-003REV_2
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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SR-20-003REV_2
! 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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SR-20-003REV_2
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.
Page 12 of 35

SR-20-003REV_2
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
Page 13 of 35

SR-20-003REV_2
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.
Page 14 of 35

SR-20-003REV_2
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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SR-20-003REV_2
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.
Page 16 of 35

SR-20-003REV_2
When using the combination below:

Anti-Corrosion Agent
Spray Gun
MZ341024EX
MZ321015 (used in

Canada)
MZ341023EX
T99XXKXX01
-
X
X

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