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gelenda
Veteran
Date registered: Mar 2012
Location: Great Bay, New Hampshire
Vehicle(s): '03 G500, '16 E63S AMG, '15 Grand Cherokee Diesel
Posts: 122
| Rusty tailgate
Having survived 10 New England winters, my tailgate has rusted through at the bottom. The MBUSA website claims the body panels are galvanized. Was this something that was always done or did they start doing this more recently?
Just trying to get an idea of how common this problem is. My plan is to replace it with a used one instead of trying to fix it.
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leomd
Member
Date registered: Nov 2013
Location: Miami, Florida
Vehicle(s): 2002 G500-Bessie
Posts: 33
| RE: Rusty tailgate
I grew up in Boston and have seen first hand the effects of New England winters/road salt on cars so I feel for you.
I have two G's, an 02 G500 and a 03 G55. Although neither of my G's have had NE exposure I still have a very small amount of rust bubling (on both cars) in the exact same spot... bottom of the tailgate, center and directly below the spare tire. I think it would be safe to assume this is a common rust area on G's especially ones that have winter/salt exposure. Im not sure about the panel being galvanized, with the rust showing I would assume in later G's but not ours.
Depending how much rust you have I would try a trusted body shop that can cut out/replace or grind out depending on how bad it is. Is the bottom of the door open as in rusted thought or is it a small rust spot bubling through the paint? My concern with a replacement new door would be the cost of the door + the repaint/refinish and then you have to wory about the same rust coming back. You may get lucky and find a paint matching used door with no rust but I assume they would sell you the door for twice as much as a good body shop would charge for a repair.
good luck...
Edited by leomd 10/12/2014 5:10 PM
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94rover
Veteran
Date registered: Oct 2010
Location: 39.2036° N, 76.8569° W
Vehicle(s): 02 G500
Posts: 240
| Re: Rusty tailgate
Raising my hand to indicate that I too have three rust bubbles spread out underneath my spare at bottom of door. I try to look away (ignore) with hopes of one day being able to treat "the bubble growth" before it takes over the entire bottom half of door. |
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03-Gwagen
Elite Veteran
Date registered: Apr 2006
Location: Western Pennsylvania
Vehicle(s): CLK63 Black Series, 2018 G63, 2016 GLE300d
Posts: 888
| Re: Rusty tailgate
I used POR15 every time rust started there on my 2003.
And it worked.
But then there was rust blistering from under the rear door handle. The bolts holding the handle on the door were rusted solid. Heat and PB blaster didn't work.
That was the final straw.
Traded it on a 2014 G.
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sjtymko
G-Class Photo Host
Date registered: Apr 2006
Location: Canada, AB, Sherwood Park (Edmonton)
Vehicle(s): 2002 G500, 2009 B200
Posts: 511
| RE: Rusty tailgate
Also the bottom of the door...and around the handle...and a few spots here and there elsewhere on the truck. One of these days, I think I have to get out the sander and clean it all up and repaint. Having removed my running boards has meant my hinges have taken a beating as well as many small 'dings' on the lower half of the doors. I hate rust! Steve
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gelenda
Veteran
Date registered: Mar 2012
Location: Great Bay, New Hampshire
Vehicle(s): '03 G500, '16 E63S AMG, '15 Grand Cherokee Diesel
Posts: 122
| Re: Rusty tailgate
The entire bottom of the door has rust on it all around and at this point there is a hole in the outer sheet metal big enough to stick a finger into it.
There's also rust around the rocker panels as well as the rear left quarterpanel above the G500 decal. I was quoted $3500 (minimum) for fixing that as well as cutting out and replacing the bottom of the door.
I've already located a cheap used door even though it's the wrong color and requires some body work but it is rust free.
Edited by gelenda 10/13/2014 11:01 AM
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leomd
Member
Date registered: Nov 2013
Location: Miami, Florida
Vehicle(s): 2002 G500-Bessie
Posts: 33
| Re: Rusty tailgate
I assumed you just had a small spot and didn't realize the bottom of the door is rusted out. In your case a replacement door sounds like the best solution.
Edited by leomd 10/14/2014 6:39 PM
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NHDave
Extreme Veteran
Date registered: Dec 2013
Location: Seacoast NH.
Vehicle(s): 2004 AMG
Posts: 464
| RE: Rusty tailgate
My 04 manual shows galvanizing on all door panels, I hope so! Salty winter roads here in NH.  |
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BlueG
Elite Veteran
Date registered: Aug 2009
Location: DC
Vehicle(s): 2003 G500
Posts: 714
| Re: Rusty tailgate
Do any of you with rusty tailgates also have rust around the rear washer nozzle? The bottom of my tailgate is a little rusty under the seal - and it can easily be stopped with POR15 under the seal. But the rear washer nozzle on mine is all bubbly all around and needs body work. If anyone has had this issue please let me know if its from an internal leak from the washer fluid or just from salt/water getting under the seal. |
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mb230s
Date registered: Apr 2006
Location: SWFL
Vehicle(s): G-less for now, vintage MBs, FJ40
| Re: Rusty tailgate
You may want to check MB's corrosion warranty. It's a lot longer then the original warranty and while not a secret isn't well known. My 2002 had rust visible on hinges, various seams, and the rear door back in 2009. MB repaired/repainted a good chunk of the vehicle...which had the added bonus of including a new windshield. After it was all fixed up I decided the truck couldn't look better and sold it!
Unfortunately I think the early years of water based paint were problematic as was the DC merger. |
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gelenda
Veteran
Date registered: Mar 2012
Location: Great Bay, New Hampshire
Vehicle(s): '03 G500, '16 E63S AMG, '15 Grand Cherokee Diesel
Posts: 122
| Re: Rusty tailgate
I'm not the original owner (first owner was a lease for about a year) so I doubt I would qualify for the goodwill warranty or whatever they call it. There is some surface rust on the hinges which I've had for a while. But I was able to get the rear door replaced without spending a fortune. I found a slightly banged up door shell from California on Ebay and had a local body shop fix it up and paint it so it looks brand new.
There was also rust under the doors so I had them remove the plastic trim pieces and put a strip of Line-X coating where the trim used to be. It looks much better now. The door panels are probably galvanized since they are holding up much better.
The hood is probably the next thing needing attention as well as the windshield frame. There is rust developing all over the underside of the hood and tiny rust spots on top from where the paint has chipped. |
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Aircruiser
Extreme Veteran
Date registered: Aug 2011
Location: Atlanta GA
Vehicle(s): 2000 G500, 1986 300GD, 2017 Porsche Cayenne Hybrid
Posts: 364
| Re: Rusty tailgate
My rear door has been worked on by a shop once since I have owned her and at least one other time in the past. It had spent some time in Pa in a past life also. I replaced/patched the lower rear door bottom center section with good steel after my last rear end accident. The shop, a European car restoration expert in the area, said that the dissimilar metal from the door stop mechanism added to chinks in the paint armor from stress of rear tire carrier and previous damage had started the rust in that area. All other areas from what I have seen in my G are still rust free. I have removed all door pannels and proactively inspected and treated common 460 problem areas. I Hate rust! |
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gelenda
Veteran
Date registered: Mar 2012
Location: Great Bay, New Hampshire
Vehicle(s): '03 G500, '16 E63S AMG, '15 Grand Cherokee Diesel
Posts: 122
| Re: Rusty tailgate
Aircruiser - 2/23/2015 10:08 PM
My rear door has been worked on by a shop once since I have owned her and at least one other time in the past. It had spent some time in Pa in a past life also. I replaced/patched the lower rear door bottom center section with good steel after my last rear end accident. The shop, a European car restoration expert in the area, said that the dissimilar metal from the door stop mechanism added to chinks in the paint armor from stress of rear tire carrier and previous damage had started the rust in that area.
I agree that the tire carrier likely contributed to the rust problem, probably by causing the door to vibrate when going over bumps. Although I admit that driving on unpaved roads for years didn't help. I don't carry a spare tire anymore and removed the carrier hardware and plugged the holes. |
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TD1
Member
Date registered: Apr 2015
Location: Brooklyn, NY
Vehicle(s): 2004 G500 // 97 Disco
Posts: 22
| Re: Rusty tailgate
Reviving this thread as I am coming up on a similar issue. Besides eBay, does anyone have source for procuring either a door shell or an entire assembly?
Thank you. |
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markvulture
Regular
Date registered: May 2006
Location: kent england
Vehicle(s): 300gd canvas top plus several g projects!!!!!
Posts: 54
| Re: Rusty tailgate
Rear door skins are available, part number is 4607421609. cost should be of the order of 360 euros max. There is a thread on the g wagen register in the uk, sign up and check it out! |
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BlueG
Elite Veteran
Date registered: Aug 2009
Location: DC
Vehicle(s): 2003 G500
Posts: 714
| Re: Rusty tailgate
I took a close look at mine and its just surface rust under the seal. I am going to wire brush and POR15 coat it. If you can pull the door and lay it horizontal, welding in patches is a good way to repair it instead of replacing the door. Door bottom rust is much easier to repair than things like lower fenders. Usually door bottom rust is much lower and concentrated. If you cut out the rusty section, the relatively flat surfaces wouldn't be too difficult to repair for someone who knows how to weld automotive panels. I am not sure if it is galvanized however. If it is galvanized or coated in any way then the rust repair would be more difficult because welding on anything but bare steel poses welding difficult and serious health hazards unless properly equipped. Nonetheless, if you take the door off and have it repaired and painted you would have no body work to do on the chassis fitting a different door. |
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