What will rust on a Discovery SI?

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Author Message   Joe Posted on Thursday, October 24, 2002 - 09:15 am:    I live in the rustbelt and am looking at some 96-98 Discoveries. I know the outer skin is aluminum. But where should I be looking for rust? I see the bumpers, bumper mounts, tailgate are steel. Any other suggestions on where to inspect for rust would be appreciated.   Jeremy Katka (Jkatka) Posted on Thursday, October 24, 2002 - 11:15 am:    The roof especially around the alpine windows. JK   Robert Sublett (Rubisco98) Posted on Thursday, October 24, 2002 - 11:27 am:    In the door jams, especially in the rear. My rig came from Boston and it is rusted really good there.   Luc Posted on Thursday, October 24, 2002 - 12:32 pm:    Here in the UK you will find rust on most disco I, something to do with the weather... Check all door bottoms where you will find electrolytic corrosion bewteen the aluminium skin and the steel frame. The sills under the plastic trims are also likely to rust depending on where the car has been. Look underneath the truck and check the frame, around the outriggers and rear-cross members. Also look aroud the underneath of the body and check that the undercover protection (black thick paint job is not damaged with rust showing along weld lines, especially along the plate above the fuel tank. Get in the back of the car and lift the rear load cover. The steel plate here rust badly and it is not unusual to change it, here in the UK. Open the bonnet, sorry the Hood, and check along the inner wings and in and around the battery area; again common rust spot, easy to fix. Last but not least check the body mounts, inside the rear doors where water gets trapped, alpine windows, inside rear wheel arches and rear bumper top. Good luck... Luc   E Snyder Posted on Thursday, October 24, 2002 - 03:53 pm:    Good post, Luc. I'm seeing the beginnings of rust in some of those places on my truck as well. I'm most worried about around the alpine lites. Seems like that would be a pain in the ass to fix if it gets too far...   John Posted on Thursday, October 24, 2002 - 06:29 pm:    Also check the back door. My 95 came from michigan, and the back door was rusted out. Had to get the whole thing replaced. Look at the bottom of the door. If there's any rust, you'll see it.   muskyman Posted on Thursday, October 24, 2002 - 11:06 pm:    Ive seen a dozen with the top hinge on the back door 100% rusted no more paint left ... but never the bottom hinge?   Grant Lawson Posted on Friday, October 25, 2002 - 12:56 am:    lets not forget about the corrosion warranty!!   Luc Posted on Friday, October 25, 2002 - 05:02 am:    E Snyder, The rust on the Alpine is not a big problem to fix. You must however get it done early enough so that you avoid any water ingress and perforation of the steel underneath that rubber seal. The plastic trims inside the car need to come off which is not too big a job if procedure is followed. The trick is to get it done by someone who knows about LR; it will be a better job for a lot less money... Luc   Joe Posted on Friday, October 25, 2002 - 01:43 pm:    Thank you all for the advice, especially the tips from Luc. I am now much better prepared to look at some vehicles. Regards, joe   Dobie Disco (Mary) Posted on Thursday, October 31, 2002 - 11:39 pm:    Anyone have the work done under warranty?   Alan Yim (Alan) Posted on Friday, November 01, 2002 - 01:09 am:    I had rust on the dog legs of the back door wheel wells which as I understand it, is a common problem with Discos...at least D1's anyway. I think warranty should cover it but I'm not sure. My warranty on my 98 D1 ran out in February of this year but I caught the rust in July however, LR offered to pay to have it fixed so I got both sides done for free...not gonna have to ask me twice! A   William C. Leek (Onionman) Posted on Friday, November 01, 2002 - 08:40 am:    I had rust repaired on the rear door jambs (the "dog legs") last year. I thought it would be under the rust warranty. My dealer said that it would not be covered because the warranty only covers body surfaces. The door jambs don't count as part of the surface of the body. They did the work for me for free anyway under their own "good will" policy. Next week, I have an appointment with the dealer to repair part of the same area that is beginning to show more rust. Also, to have a spot of rust repaired around one of the alpine windows that has just recently appeared.   Milan (Milan) Posted on Friday, November 01, 2002 - 11:00 am:    Alan, How much rust did you have there? One of my door jambs has a buble there and I thought the warranty was for rust-through situation not just surface rust. I'd like to get it fixed before my warranty runs out next week.   Alan Yim (Alan) Posted on Friday, November 01, 2002 - 02:18 pm:    Hi Milan, The rust on the driver side dog leg was about the size of a quarter and was just a bubble. It hadn't really burst open. The passenger side dog leg was just beginning to show...like the paint cracked a bit but you could see the beginning of corrosion. All in all, the total to fix those two spots was around $2000 (sure glad LR paid for it) but the dealership here in Edmonton sends all their work to a high end specialty shop (Modern Autobody - don't know if they have a shop in Calgary or not) that only deals with vehicles like Mercedes, BMW, Jags...so not sure how much of that price was actual and how much was reputation type thing. But I have to say, they did an AMAZING job...I'd take my truck to these guys if I wanted my truck repainted...and won the lottery. When I asked the dealership about why they were paying for it, even though my warranty ran out almost 6 months prior, they said that it was rusting in an odd spot that shouldn't be rusting but was an apparently known problem to them so they offered to pay. The answer kind of surprised me as I'm guessing most dealers would say "too bad" and not offer to do anything about it but maybe they were doing a goodwill thing or something. The guys there know me as I typically will go to all their off-road events and but who knows. I was just glad they fixed it or else I was going to pull out some hockey tape and do my own patch job. If you're interested, Milan, I can probably take some digital photos of the area they worked on for you to see what was done. Let me know. A   JEN STOLEN (Rovr4x4) Posted on Friday, November 01, 2002 - 06:52 pm:    I have a 92 RRC and from what I can see the only parts that don't rust are the ones made of plastic, they just become brittle and break instead. My truck came from the same factory as yours and everything on it is slowly returning to the earth.   Milan (Milan) Posted on Saturday, November 02, 2002 - 11:21 am:    Alan, Mine is only on the driver side but I'm pretty sure my dealer will deny the warranty. So I'd like to give your dealer a try if they do. Do you have a contact there?