So I too recently fell victim to the dreaded W204 rusted subframe. I was just driving down the road one day, felt a huge clunk, my steering went a little haywire (it's now cocked with the top center pointing at about the 10 o'clock position). When I applied the brakes, it was like the rear end was on shopping cart wheels....scary.

My pic shows where the lower control arm rusted and broke right off from the subframe.

Took it to my Merc dealer and they will be covering the subframe repair (under the extended 30yr warranty). Awesome. However, they are getting me for $1300 to repair an exhaust section that needed repair in order for the subframe to be fixed. Basically, I was held hostage to pay for the exhaust repair. Anyone run into this situation when having the subframe addressed at the dealer?

Seems kinda crappy but I can only be grateful that I am not also paying for the subframe (5k plus job I am guessing).

Oh well....it's been a great car for me with my only other major issues being the failed ESL and a bad transfer case bearing.

 

Was the exhaust damaged from the subframe breaking? if so I would argue about it.

Did you get a written estimate of everything they will be replacing? Look thru it, now would be a good time to have anything else worn replaced like control arms, sway bar.

What exactly is wrong with the exhaust?

 

I kinda see their point. A part of car ownership is taking the responsibility to keep your vehicle safe...you - could - have inspected it prior and had it replaced prior. You could have taken it to any MB dealership for a free inspection. You chose to ignore it until it was too late.

 

Nice write up

 

$5k for subframe replacement alone is a joke. My local dealership (who are also jokes), wanted somewhere near $7k. They like to mark things up about 100% give or take from other dealerships I've spoken to.

I have a Benz indy nearby I use for bigger jobs I can't do, like this one. I was either at or just under $2k for a new subframe on my C207 chassis. My brake lines were fine as well as exhaust. I don't let winter road salt sit on the car at all & it is cleaned weekly all year. However I DEEPLY regret not having all suspension arms done (as well as the upper diff mount) during the subframe job. I was in disbelief that a (then) 100k mi car could actually need EVERY SINGLE rear bushing done. I thought my slop was only from the noticeably trashed subframe bushings, which also make 0% at 100k mi on a gently driven car on average roads.

I actually had the subframe replaced because it was far less work & 200% more cost effective than doing the bushings alone, which speaks to the laughably horrendous design and materials used in these pathetic rear ends. Benz has LARGELY regressed here on these chassis. There's 400k mi W124's in Morocco on original subframes & rear suspension I guarantee you.

MBUSA reimbursed me through my local dealership for the costs I paid for this job at my local indy, as all who work at my indy are from that dealership & they have a great working relationship. (Regardless of this, I think one will still get reimbursed.) I would recommend the same if still possible and save yourself from a $3-4k mark-up.

 

I was thinking of contacting MB direct for support on the exhaust repair. How did you contact them?
I have to find the pic from the tech but it was part of the exhaust piping that snakes up and over the rear axle (passenger side). Basically, unless someone was really digging into it, it would have been tough to find. I've cared for my W204 well and during winter, since it's my daily, it get full wash 2-3 times a month...which is plenty but sometimes I wonder how well the undercarriage wash really cleans. Unless you use it 3-4 times in a row, it's not getting everything cleaned. What can one do in the middle of 15* winter...go outside, crawl underneath and wash everything else with a brush? Poppycock!
It's been a great car but the truth of the matter is, I'm trying to keep her going another 1-2 years. Once the wife's car is paid off, it's my turn. I've been eye-balling the CLA 35 and 45's. I just love the look of the CLA and their power with the AMG's are better than my M276. The 35 is 302 and the 45 (AMG handbuilt), is 400 something.

 

As far as contacting MBUSA, it was all done by a Service Adviser at the dealership. I personally had no contact with them myself. The indy told me to call the service dept at the dealership and make an appointment with receipt in hand.

I went in and met with an SA for maybe 5 mins, told my tale of woe and gave him receipts to make copies of. He was very sympathetic and helpful, even urging me to not say too much as then I don't think the recall was 100%. It was more a goodwill job or reimbursement type thing. He said if all works out, MBUSA will send a check in the mail. I believe it was around 2 wks after the meeting that a check showed up.

As for your exhaust, is it one of those curved mounting points that has the rubber exhaust hanger on one end? There's about 6 back there if memory serves.....some bolt up to the chassis & some bolt up to brackets, like the one central bracket above the diff. I do know Mercedes will happily quote you an exhaust if you actually just need one mounting point re-welded, etc. My sister has a late W203 & this happened to her. I needed to drop her exhaust for upstream 02's & wouldn't you know.....her exhaust is completely fine regardless of a few brackets that winter had claimed. 1 trip to an exhaust repair shop and maybe $170 total (new brackets/hardware I bought from Benz & exhaust shop labor), and she was back on the road.

Your situation might be more tricky if the car is already at the dealership. I guess it would be an awkward call to say, "give me my car back so I can have an exhaust shop do what you can't/won't & I'll be back for my subframe!" Then again, hopefully you can as it's your car.

And yes, it definitely is bs and unrealistic to go outside in the depths of winter to keep an underside squeaky clean. I'm the weirdo in my garage at night with spray bottles and a will to let it live well until the next owner! I'm going to fluid film some in the coming weeks. I'll usually bring some Super Clean or DIY Detail Rinseless with me to a self service power wash station, soak the undercarriage and blast it off. I guess it's been working well, but like you said, I'm sure I could spot something new the next time I'm under there regardless of my efforts.

 

ok....not really complaining here...