M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

Rust Problems on rear hatch and rockers

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Old Oct 20, 2005 | 02:00 PM
  #1  
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Rust Problems on rear hatch and rockers (with pics!)

First off, hi everyone, this is my first post on mbworld... I usually am on Audiworld or on VWvortex

I have a 2003 ML 500 with 88k miles and recently rust has been forming in strange places. First there are bubbling patches on the top of the rocker panels, sort of on the door sill/jam area where the plastic skirts fit over the steel doorjam.

THere is also rust on the rear hatch along the inside of the top edge because the hatch has been rubbing on the weather stripping that runs along the top (its attached to the roof). Im guessing that the stripping is out of alignment (too high) and this is causing the rubbing. Also there is just the smallest hint of rust on under the chrome strip that covers the rear hatch release handle.

Has anyone had similar problems, especially with the rear hatch weather stripping? Mercedes claims to have never seen nor heard of any other MLs with rust in these spaces and has agreed to pay half of the repair costs, but I would still like to get as much info on the problem as I can.

Thanks!

Jon
Attached Thumbnails Rust Problems on rear hatch and rockers-mlrust-002-medium-.jpg   Rust Problems on rear hatch and rockers-mlrust-004-medium-.jpg   Rust Problems on rear hatch and rockers-mlrust-005-medium-.jpg   Rust Problems on rear hatch and rockers-mlrust-007-medium-.jpg  

Last edited by lookaught; Oct 20, 2005 at 02:37 PM. Reason: pics!
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Old Oct 20, 2005 | 02:05 PM
  #2  
55fanatic's Avatar
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00 MB ML55, 91 Toyota Supra Turbo(sold), 06 E500(gone), 03 BMW M3
nop, I have some rust forming on the inside of the drivers door, thats about it... Mine is a 2000 ML55 with 93k miles
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Old Oct 20, 2005 | 02:13 PM
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2010 ML550, 2010 E350 4M, 1966 Corvette Convt C2
Never had any on either my 98 or the 02 I just traded. Could it be possible that your ML had been hit and improperly refinished??
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Old Oct 20, 2005 | 02:16 PM
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Originally Posted by sosh
Never had any on either my 98 or the 02 I just traded. Could it be possible that your ML had been hit and improperly refinished??
No its never had any paint work whatsoever. I believe the rocker rust is forming b/c the plastic skirts are rubbing through the paint. The rear hatch is a mystery to me...
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Old Oct 20, 2005 | 05:53 PM
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00 MB ML55, 91 Toyota Supra Turbo(sold), 06 E500(gone), 03 BMW M3
Originally Posted by lookaught
No its never had any paint work whatsoever. I believe the rocker rust is forming b/c the plastic skirts are rubbing through the paint. The rear hatch is a mystery to me...
has it been in a flood? When you wash your car do you dry out your door sills and such? What could be happening is that water is making its way through the seal and just sitting and forming rust, not a great thing
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Old Oct 21, 2005 | 12:12 AM
  #6  
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From: Toronto Ontario Canada
98 ml 320, MGB GT V8 (FACTORY)RHD
My 1998 ML320 is rust free, but it was a original west coast car. I just sold my 1999 C43 which had the same problems as your ML, It had rust on the drivers door where the molding touches the paint. Around the sunroof, plus six or seven other spots. The odd thing is that underneath the car was perfect not a touch of rust, but this car had spent most of its life back east (Toronto) Mercedes would do nothing for me ( The car was a 1999 so I did not expect much)
Best of luck,
Mike.
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Old Oct 22, 2005 | 12:42 PM
  #7  
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'05 A4 1.8TQM6
rear right door on our ML, three decent sized rust bubbles along the edge of the door, ugh.
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Old Nov 16, 2005 | 08:52 PM
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Yes

Your not crazy, I have the same thing. Same color also. They gave me the half price BS too. This color and or paint application is defective, end of story.
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Old Mar 30, 2009 | 12:15 PM
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I have some nasty rust going on near the license plate. I'll take a pic soon.
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Old Apr 2, 2009 | 02:13 AM
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02 W163
what you can do for now is get WD 40 rub some of the rust off then put some clear coat on it....that would help protect the rust from spreading..
i think i have some rust problems too, but i never really check.
In vancouver we had WAY TO MANY SALT ON THE ROAD
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Old Apr 3, 2009 | 01:38 AM
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Originally Posted by STi_JL
what you can do for now is get WD 40 rub some of the rust off then put some clear coat on it....that would help protect the rust from spreading..
i think i have some rust problems too, but i never really check.
In vancouver we had WAY TO MANY SALT ON THE ROAD
NOOOOOOOOOOOOOOOO WD40 on paint... are you thick? appropriate way to take care of the situation is to sand away the trouble areas, clean with mineral spirits... prime then paint... in a week or so cover the area with a wax... LOTS OF IT
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Old Apr 3, 2009 | 03:17 PM
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LOL
Don't worry Pete. I know better than to spray WD40 on my paint. I'll try sanding some spots down and but some anti rust spray on it.
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Old Apr 3, 2009 | 03:48 PM
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Originally Posted by Stiggs
LOL
Don't worry Pete. I know better than to spray WD40 on my paint. I'll try sanding some spots down and but some anti rust spray on it.
I dont want to alarm you stiggsy but it could very well be too late for your hatch area...
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Old Apr 4, 2009 | 10:46 PM
  #14  
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02 W163
i just check my rear bumper when you open the trunk.
i see spots of rust, but its not eatingthe paint or anything.. ill try to rub it off with some glue remover,
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Old Apr 5, 2009 | 02:09 AM
  #15  
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2000 ML55 (parted out), 92 1jz SC300, 92 Sentra (DD), 05 Cadillac SRX
My hatch is rust free and I still have it left in my partout
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Old Apr 5, 2009 | 05:13 PM
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Originally Posted by 55fanatic
I dont want to alarm you stiggsy but it could very well be too late for your hatch area...
You're probably right. There is a spot near the front door that I'm gonna sand down though.
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Old Apr 6, 2009 | 12:52 AM
  #17  
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Originally Posted by STi_JL
i just check my rear bumper when you open the trunk.
i see spots of rust, but its not eatingthe paint or anything.. ill try to rub it off with some glue remover,
NO GLUE REMOVER!!! STOP WITH THE CHEMICALS!!! WOW are you really that thick? you're going to put stuff that DESTROYS paint on the car, no paint will speed up the rusting process... Give your car a propper detail
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Old Apr 7, 2009 | 08:19 AM
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Originally Posted by 55fanatic
NO GLUE REMOVER!!! STOP WITH THE CHEMICALS!!! WOW are you really that thick? you're going to put stuff that DESTROYS paint on the car, no paint will speed up the rusting process... Give your car a propper detail
LOL
STi_JL please stop.....youre giving Pete chest pains!
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