Repair Procedures

This repair procedure involves cleaning and applying anti-rust material to the inside and outside of the rear sub-frame assembly.

Exposure Controls for use of Nox-Rust X-210 and X-121 Black


























Material Safety Data Sheets (MSDS) for these products are included in each product carton and available in the electronic version.

Respiratory Protection

NIOSH-approved respirator for organic vapor and mist to control exposure where ventilation is inadequate. Example: 3M Maintenance-free Half Facepiece Respirator 07191, 07192, 07193 or Low-Maintenance Half Facepiece Respirator 07177, 07178, 07179.

Ventilation

General and local exhaust.

Personal Protective Equipment

Caution:
Avoid prolonged skin contact.

Protective Gloves: Impervious gloves (Viton, PVOH, etc.)

Eye Protection: Safety glasses with side-shields or chemical goggle.

Other Protective Clothing or Equipment: If splashing is anticipated, wear a rubber apron and boots or other protective equipment to minimize contact.





Necessary tools and supplies:

SPRAY EQUIPMENT OPERATING INSTRUCTIONS





The pressure pot is equipped with an adjustment valve (or stop screw) to adjust the ratio of product to air. This adjustment valve will have to be adjusted in order to achieve optimal spray pattern for each material. The adjustment valve is identified in the diagram.

Before filling the gun, turn the stop screw clockwise until completely closed. Draw a line down the middle of the stop screw using a marker. This line will be used to determine the number of turns needed for optimal spray of the waxes.

Settings For Nox-Rust(R) X-210 Corrosion Preventive Penetrant

When using the 360° flexible wand, turn the stop screw counterclockwise 1/2 turn from dosed, and adjust the air supply pressure to 40 psi.

Settings For Nox-Rust(R) X-121 Black Corrosion Preventive Coating
(Note: Product should he room temperature for proper application.)

When using the 360° flexible wand, turn the stop screw counterclockwise 3 turns from closed, and adjust the air pressure to 80 psi.

When using the 90° hook wand, turn the stop screw counterclockwise 3 turns from closed, and adjust the air pressure to 80 psi.

Gun Disassembly And Clean out

Important:
The spray equipment must be cleaned between vehicle applications.
X-121B (Black Wax) must be removed from the gun and lines prior to applying the X-121 (Oil) to the next vehicle. Use the following procedure for equipment cleaning.

1) Turn the spray gun stop screw (as pictured above) clockwise until completely closed
Blow the 360° flexible and 90° hook wands clear with air by pulling the spray gun trigger.

2) Disconnect the gun from the air supply.

3) Remove the spray tube using the quick disconnect.

4) Relieve the pressure from the gun by slowly turning the paint pot to the left until all the air escapes. Do not use the gun trigger to relieve pressure from the pot. This will cause the wax to flow into the air line supply of the gun.

5) Remove the paint pot and drain any remaining wax. Rinse the pot with mineral spirit based solvent.

If the gun is to be stored for more than 4 weeks, completely clean the gun with mineral spirits.

Always store the gun assembled. Do not soak the 360° flexible or 90° hook wands in solvent.

Prolonged exposure to solvent will cause damage.

REPAIR PROCEDURES DETAILS

Step 1: Raise vehicle on a lift.

Step 2: Remove the left and right rear wheels.





Step 3: Identify the component name of the rear sub-frame assembly as follows:

(A) Front Crossmember
(B) RH/LH Side Member
(C) Rear Crossmember

Step 4: Clean the entire rear sub-frame assembly

Note:
It is important that the rear sub-frame be properly cleaned in order for the rust proofing process to be effective. Use caution not to damage components such as emission lines.

(a) Clean the outside of the entire sub-frame assembly of mud, dirt, salt and other debris using a high pressure washer.

(b) Clean the inside of the entire sub-frame assembly by carefully applying high pressure water through the bottom holes of the sub-frame.

(c) Dry the inside and outside of the sub-frame assembly using high pressure air at the same locations identified in the cleaning process. Use a clean rag to remove any remaining moisture.





Step 5: Vehicle Preparation

Important:
Be sure the following items have adequately cooled before applying protective covers.

(a) Cover rotors, calipers, and exhaust parts near the sub-frame with a cloth or paper to prevent wax from adhering to these surfaces.

(b) Place a suitable container (such as an oil drain pan) below the vehicle's subframe to capture any anti-rust agent and anti-rust wax that could leak from the drain holes during the application process.

Step 6: Application of anti-rust agent (NOX RUST X-210)








Use the flexible 360° type nozzle for spraying. Turn the spray gun stop screw counterclockwise 1/2 turn from closed, and adjust the air supply pressure to 40psi Sprayed amount: 5oz. (150cc). Refer to the chart for spray times and follow the detailed, step-by-step process.

The holes in which the spray nozzle should be inserted and the direction from which the spray nozzle should be applied are identified in the figure (see steps 5 and 6) (The letter-identified areas show nozzle insertion points and dotted lines show the direction in which nozzles should be inserted.)

Spray time of anti-rust agent and length of spray nozzle to be inserted into the sub-frame corresponding to the holes located at bottom of the frame are identified in the following information.

Important:
Place a container under the vehicle to catch any excess anti-rust agent from the drain holes.

Anti-rust Agent Application Detail:

CROSSMEMBER FRONT





Insert the 360° spray nozzle into the opening (A) until it touches the bushing outer tube at the other side. Spray anti-rust agent for 8 seconds while pulling the spray nozzle back to the original opening (A).

Spray time: 8 seconds.

SIDE MEMBER LEFT & RIGHT HAND

Insert the 360° spray nozzle into the hole (B or C) located at front end of the bottom of the side member until it touches the rear bushing outer tube at the other end. This area is approximately 19 inches (480 mm) long. Spray anti-rust agent for 5 seconds while pulling the spray nozzle back to the original opening (B or C).

Spray time: 5 sec. (2 locations = 10 sec.)

CROSSMEMBER REAR

Insert the 360° spray nozzle into opening (D) located in bottom of the crossmember rear at the right end connected to the side member until it touches the side member of the other side. This area is approximately 23 inches (590 mm) long. Spray anti-rust agent for 6 seconds while pulling the spray nozzle back to the original opening (D).

Spray time: 6 sec.

Step 7: Application of anti-rust wax (NOX RUST X-121 Black).

Use flexible 360° type nozzle. Turn the stop screw counterclockwise 3 turns from closed, and adjust the air pressure to 80 psi. Sprayed amount: 13.5oz (400cc).





The holes in which the spray nozzle should be inserted and the direction fro which the spray nozzle should be applied are depicted in the figure above. (The letter-identified areas show nozzle insertion points and dotted lies show the direction in which nozzles should be inserted.)





Spray time of anti-rust wax and length of the spray nozzle to be inserted into the sub-frame corresponding holes are described as shown.

CROSSMEMBER FRONT (A)

Insert the 360° spray nozzle into hole (A) at right side of the crossmember front until it touches the outer tube of the other side bushing. Spray anti-rust wax for 12 sec. while pulling the spray nozzle back to the original opening.

Spray time: 12 sec.

CROSSMEMBER FRONT (B)

Insert the 360° spray nozzle into hole (B) at left side of the crossmember front until it touches the outer tube of the other side bushing. Spray anti-rust wax for 12 sec. while pulling the spray nozzle back to the original opening.

Spray time: 12 sec.

SIDE MEMBER RIGHT HAND FRONT (C)

Insert the 360° spray nozzle into hole (C) at front end of the side member until it touches the outer tube of the rear bushing at the other end of the side member. Spray anti-rust wax for 8 seconds while pulling the spray nozzle back to the original opening.

Spray time: 8 sec.

SIDE MEMBER LEFT HAND FRONT (G)

Insert the 360° spray nozzle into hole (G) at front end of the side member until it touches the outer tube of the rear bushing at the other end of the side member. Spray anti-rust wax for 8 seconds while puling the spray nozzle back to the original opening.

Spray time: 8 sec.

SIDE MEMBER RH / LH CENTER (picture D & E / H & I)

Insert the 360° spray nozzle into the hole (D or H) at center of the side member toward the crossmember front until it touches the crossmember front. Spray anti-rust wax for 4 seconds while pulling the spray nozzle back to the original opening.

Also insert the 360° spray nozzle into the hole (D or H) at center of the side member toward the rear until it touches the outer tube of the rear bushing at the rear end of the side member. Spray anti-rust wax for 4 seconds while pulling the spray nozzle back to the original opening.

Spray time: 8 sec. X 2 locations = 16 sec.

SIDE MEMBER RIGHT & LEFT HAND CENTER (F/J)

Insert the 360° spray nozzle into the hole (D or H) at center of the side member in an upright position until it touches the upper side. Spray anti-rust wax for 2 seconds.

Spray time: 2 sec. X 2 locations = 4 sec.

CROSSMEMBER REAR (K, L, & M)

Insert the 360° spray nozzle into the opening at left or right end of the crossmember rear until it touches the side member at the other side. Spray anti-rust wax for 8 seconds while pulling the spray nozzle back to the original opening.

In addition to the above work, insert the 360° spray nozzle into the same openings at the left and right ends of the crossmember rear in an upright position until it touches the upper part of the member. Spray anti-rust wax for 1 second. Spray time: 1 sec. X 2 locations = 2 sec.

Step 8: Application of anti-rust wax (NOX RUST X - 121 Black) to outside of the sub-frame.

Use the 90° hook wand. Turn the stop screw counterclockwise 3 turns from dosed, and adjust the air pressure to 80 psi. Sprayed amount: 20oz (600cc). Targeted layer thickness should be a minimum of 2 mil.

(1) Spray anti-rust wax onto the entire subframe surface, hem flange and welded flange of the crossmember front, the side member left and right and crossmember rear under side.

Spray time : 4 min.

(2) Lower the lift to facilitate the spray work and spray anti-rust wax onto the upper surfaces and side surfaces of the left and right side members.

Spray time : 2 min.

Step 9: Clean-up and Drying

(1) Wipe off the overflowed wax with a soft cloth.

(2) Make sure the holes located at the bottom of the members accessed in the repair are not clogged with wax. If clogged, clean the holes thoroughly.

(3) Allow at least one hour drying time before using the vehicle.