202 RUST! Beware

[chizzel89]

Still, I think my drivers side jacking point is rusty and will need welding. MOT time next week... Frustrated at Mercedes use of poor quality steel.

It's not poor quality steel, it just hasn't been kept clean. The underseal has probably taken a beating at some point and the damage hasn't been touched up and been allowed to get covered in road salt, mud etc.
If poor quality steel had been used in the W202s then you'd have rust spots breaking out randomly on the shell, even on the inside of the shell. They rust in specific places, mainly where the paint/ underseal gets hammered.
An afternoon with a grinder an a MIG welder would see that right, and with a good waxoyling the car wouldn't rot any further

 

[jama665]

Yea I just had mot dont on mine first time its failed since ive had it for 6 years. Small hole in front NS floor pan where it joins the sill. Guess its down to bad jacking at some point something to check every year or so

 

[jama665]

has anyone had issue's with rust creeping up from the where the clips are on the bump strips of the doors!

Sorry dragging old post up but just wondered if its a common rust area!!! for the w202

 

[newbitz1957]

has anyone had issue's with rust creeping up from the where the clips are on the bump strips of the doors!

Sorry dragging old post up but just wondered if its a common rust area!!! for the w202

They all do it.. even the old ones!!!

 

[adam87]

has anyone had issue's with rust creeping up from the where the clips are on the bump strips of the doors!

Sorry dragging old post up but just wondered if its a common rust area!!! for the w202

Got some nasty rust on my drivers door just above the door strip, starting to creep in on same place the other side too. It lines up with the wing mirrors where water runs down the door then sits in the little gap. My whole car could do with a respray but underneath is pretty darn good! Only the smallest bit rust just infront of the rear wheels which is going to be treated properly soon.

 

[KillerHERTZ]

I recommend everyone do this even if your car appears to be rust free.

Ive just removed my sills and found some, no holes but a fair amount which I will be grinding out.

I cant believe there is no rust proofing under the plastic sills, lazy, cost cutting from MB.

The pre-facelifts had sealant all over the sills

What do you all recommend I get to seal it up?

 

[chizzel89]

Something mucky and oily, and lots of it. Paint is bound to fail sooner or later. I favour grinding as much rust out as is possible, treating, then zinc primer X 2, then black waxoyl underseal, then a damned consistent lashing of liquid waxoyl over the top. Keeps it sealed for years and years.
I had some nasty flakey areas on my old Ford Capri which I dealt with by simply scraping off all loose rust, then treating thoroughly with Kurust, then covering it with waxoyl. I topped the waxoyl up every year, and 4 years later there was no further corrosion at all. Rust immobilised.

 

[gurpz]

What do you all recommend I get to seal it up?

This stuff is highly spoken off and can be used almost everywere and offers good protection:

http://www.bilthamber.com/pro-introduction.php?cname=CorrosionPrevention&name=dynaxS50

Dynax S50

 

[Cabe]

You'll remind me to ask you to check the usual suspects when she's next in, won't you Olli?

 

[KillerHERTZ]

Ive got mine booked in with the Body Shop next month as the rust was worse than I thought

Not as bad as the OP one, but not far off. The bodyshop had a good look and poke around, no holes as far as they can see and said they could get the work done no problem...

All facelift owners, have a good look under your car before its too late!

 

[NW_Merc]

I did this check and found the rust under the sealant on the pre-facelift..... now one question is:
Are the grommets which are on the underbody to blank the holes available from any motor factors or on the internet or do I have to go to the stealer?

 

[KillerHERTZ]

I doubt even a stealer would have them, they are rubber which is stretched like a drum, its not a pin or anything only a disc.

 

[KillerHERTZ]

Look at the horrors I have uncovered:

And the true horror:

Ive booked it into my local bodyshop, they had a good look at it and as far as they can tell it has no holes which is good.

They are going to grind it back to the bare metal properly, weatherproof it etc at the start of May.

EVERY W202 owner needs to check their car, until I removed my sideskirts to replace with the C43 AMG ones.

I had no idea, nothing was visible under the sideskirts. - one thing to look for though is a brown staining around any of the toweye covers etc which I can now see on the old sideskirts.

 

[DRBC43AMG]

I wonder what I will find when I take the side sill off

 

[KillerHERTZ]

I wonder what I will find when I take the side sill off

 

[cazyp]

Are the sill covers easy to remove/refit?
Any guides anywhere?
Cheers

 

[KillerHERTZ]

Are the sill covers easy to remove/refit?
Any guides anywhere?
Cheers

Takes about 15mins a side.

-1st remove all the tacks/clips underneith the car, theres about 6 a side and will most likely snap when removed. - prise them off.

-Then unscrew the screws at the front

- Open both doors and you will see the top of the sideskirt, carefully use a strong plastic knife or somthing which wont damage paintwork and prise it off.

It should then come off and prepare for the worse!

 

[NW_Merc]

I doubt even a stealer would have them, they are rubber which is stretched like a drum, its not a pin or anything only a disc.

So I couldnt use a run of the mill grommet then?

 

[KillerHERTZ]

It just needs to be held in place I think, so if you can seal it, yes.

 

[andy27168]

I,m dreading taking my side skirts as i know i have some rust issues with the front jacking points, and i have a rust blister which dissappears beneath the skirt from the N/S rear door shut