JD101b

I've posted before on my 2010 G-550...55k miles, very well taken care of, and rust bubbles forming under the front windscreen, around the rear door hinges and along the side door sills.

I'm going back and forth with Mercedes to see if I can get them to correct these issues. Even if they do, I still need to figure out long term preventative strategies to prevent this from happening again. So far, they include lubricating all hinges with LPS on a weekly basis and running a dehumidifier in my garage, along with using fans to dry out the undercarriage, but I'm not sure how to go about protecting the chassis, or rust proofing hard to reach areas (i.e. the underside of the doorsills or the metal directly below the front windscreen.

Does anyone have experience in rust restoration/prevention? What are my options?

haa

Also don’t forget lifting the bottom end of the rubber seal around the windshield, lots of water is always trapped under that seal after rain or car washes

carforhire

Any photos of the current rust? How bad is it? Do you feel the humidity levels in your garage are high? Good luck

places

I would be curious to hear about preventative measures as well.

drew138

I had a 2010 G55. Had the rust bubbles under the windshield. This is a major issue. MB agreed to repair the rust when the estimate to do so was $2500.00. When they finally got the car in the shop and started the repair job it became clear very quickly that there was a lot more going on. The repair ultimately entailed welding a whole new frame around the windshield frame and required input direct from MBHQ on maintaining structural integrity. There were several other areas of concern. Be sure to check the sunroof surround. I learned that MBUSA makes zero mention of rust and corrosion on their website or in the warrenty. Personally, I'm convinced that certain 2010 Gs have a systemic rust issue if the weather conditions are not perfect.

JD101b

The other areas are too small to really see in photos.

MBUSA has already fixed several spots on the door sills. I'm guessing that there is rust forming on the drivers side currently (all doorsill rust was on the passenger side).

JD101b

Preventative measures as of now include a dehumidifier in the garage (set to 15%), fans circulating air under the chassis and WD40 on all door hinges as well as around the rubber stripping on the windscreen and rear door hinges.

Going forward, I'd like to get under the chassis, sand off any surface rust, apply a rust converter and several coats of Rustolium flat enamel to the entire underside. When the underside is cured, I'm going to apply a coat of either fluid film or LPS. However, I'm worried that hard/impossible to reach areas (the doorsills, the windscreen, the rear door hinges, etc) will remain untreated or inadequately treated. For example, as Drew138 stated, the sunroof will be a very difficult area to rustproof (and who the hell rustproofs the ROOF of a truck?)

carforhire

Great place to start, keep us updated and good luck. Was it always garage kept?

horse86

wonder if its better to keep it outside in the winter with the snow/salt? Seems like keeping in in the garage caked in salt and trapped humidity could make rust conditions worse.

places

Definitely not. Just keep it clean and in a drier environment. I do wonder if there is a way to coat the vulnerable areas. I.E. the seal around the windshield, could you seal it with a ceramic coat?

horse86

goes against what this vehicle is designed for. For me it would be a DD and that mean salt/winter driving and sitting outside. If I wanted a garage queen I'd use G wagon money on an exotic.

places

Totally agree, however the issue remains.

horse86

This is the only reservation I have with getting a G as opposed to a L405 RR.....those tend to not have as bad of an issue with rust these vehicles do

places

RR's have their own issues. No comparison to a G.

horse86

RR is and has been far more luxurious than the G...The G has only started to close that gap with the 2019 model. They both have comparable power (ATB vs G63). Off-roading may have a slight nod to G63 (RR is very capable)....actually the 550 would be better offroad and then it’s under powered compared to the RR ATB. So I wouldn’t say it’s a no comparison. I’m looking at G’s to change it up a bit and I genuinely like the G. Comparing my L322 which ended production in 2012 to the pre-2019 it’s like stepping into a similar vehicle which is why I like the pre-2019 except the L322 is still more comfortable and luxurious with a 6 year difference.

And as far as rust goes...RR is much more less prone and less trouble areas.

places

No disagreement, range is more luxurious. Off-road, most civilians won't push the limits anywhere near 50%. The fact is just that there is nothing like a G, that was my point. If you want daily comfort, sure, go RR. The G is more emotion provoking than the range. Nothing feels like a G.

fabbrisd1

"RR is much more less prone and less trouble areas." - I really got a chuckle out of your comment - thanks !

horse86

Really? Have you owned one? B/c the only areas or should I say area on the L322 that are prone are cheap fixes. The paint on my L322 is so thick it feels like a gel coat in comparison to the thin G class paint. Its common place to see rust on G's after just a couple years. My L322 is 10 years old and only has rust in one area and its been DD in salt/winters every year.


RR L322:

Bottom weld/edge of tail gate. Grind away and repaint $. At very worse buy new tail gate $$


G:

Windshield = weld in a entire new frame $$$
door/door sills = Weld in a whole new section $$$
area below tail lights = weld in entire new rear quarter panel $$$
area below roof on the rear = grind away and repaint $
hinges = replace/repaint $
Moonroof! = How does a car rust on the roof!

places

Then buy the RR and be done with it. Obviously the G is not for you.

horse86

I have one and ultimately do want the G for a change of scenery....this is really the only thing that I'm concerned about. Other than that I love the G.

motorwerksgroup

Hate to say it...owning a Mercedes-Benz collision center...ALL those preventive measures will eventually fail...the rust WILL win. Just poor workmanship on behalf of Mercedes-Benz...

n3rd

Do you foresee this being an issue on the new g?

places

One thing I noticed is that these trucks have a lot of flat spots. Water doesn't always runoff that easily.

Festertester

The hood and the doors are aluminum on the new g. One can only imagine that there would be more rust proofing measures on the new ones as technology has progressed and it’s MB we are talking about but the issue is that most of the other parts are steel, I’m sure it’s all galvanized (standard industry practice) but I’m not sure what else protection wise is there?

range rover on the other hand is 100% aluminum, at least L405 that I know of. I had a rattling issue on my 2016 and it went to a special shop which specializes in Al riveting...

JD101b

Could you elaborate a bit on this? Is it a problem with the paint? The metallurgy? Etc...