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#1 2015-04-19 22:38:32

countriccati
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From: Boston
Registered: 2015-02-18
User Number: 28345
Posts: 247

Rear strut tower rust info?

Over on NASIOC there's a thread about rear strut tower rust starting from the bolts used in the rear seat bracket on 02-07 impreza wagons: http://forums.nasioc.com/forums/showthr … ?t=2391932

The gist of it seems to be the bolts undermined the factory undercoating, and the rust starts from the inside out. The only way to tell for sure is to take apart the rear part of the interior trim.

Does anyone know if this is something to watch out for on the 9-2x too?


me and my aero

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#2 2015-04-19 23:29:07

iamchris
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Re: Rear strut tower rust info?

If it's an issue on the Imprezas, it will be an issue on ours.

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#3 2015-04-20 07:25:40

itsnotmeitsyou
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From: San Antonio, Texas
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Re: Rear strut tower rust info?

Good thing I had to take all that out to install my Oswald Performance rear triangle brace.  No sign of rust but the car has spend 90% of it's life in Texas smile


2005 Saab 9-2x Aero:  More than you've had done to your car.
2015 Forester XT 'TS' clone

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#4 2015-04-20 14:19:19

krazykarguy
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Re: Rear strut tower rust info?

I have a solid car cleaning coming up soon. I will take my back seat out and report back. My car did over 100k in Vermont. I hope it's not too bad yet. Both my rear fenders are bubbling and my rear hatch corners are crusty...


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#5 2015-04-20 18:32:19

krazykarguy
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Re: Rear strut tower rust info?

Pics...
http://i934.photobucket.com/albums/ad184/krazykarguy/E257AEA3-CB26-4636-AF87-03AD506BE0FE_zpsqbpvjtmf.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/8800984C-5F5E-4595-86C0-25A99B8530D9_zpsalyyo3fj.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/95F94F4A-EF17-4CB9-A561-7A4DFF278BAE_zpsnfm9p8ij.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/5786EA73-93CE-4C73-BF6A-10853996488A_zpsx49stqc5.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/DA57D9EA-2E75-4469-8485-DC502C913854_zpsxqczlgzk.jpg


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2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#6 2015-04-20 20:05:26

iamchris
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Re: Rear strut tower rust info?

eek

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#7 2015-04-20 20:15:24

itsnotmeitsyou
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Re: Rear strut tower rust info?

Damn, made me realize I hadn't inspected that far up when I did my install.  Thankfully the rear interior is still out.  Confirmed that mine are rust free.
This should be a fucking sticky for people to know to get it checked if they live up north!


2005 Saab 9-2x Aero:  More than you've had done to your car.
2015 Forester XT 'TS' clone

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#8 2015-04-20 20:37:23

iamchris
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Re: Rear strut tower rust info?

vr4ownzyou is a genius

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#9 2015-04-20 21:04:44

ikbrown
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From: Fair Oaks, CA
Registered: 2011-10-06
User Number: 6094
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Re: Rear strut tower rust info?

iamchris wrote:

vr4ownzyou is a genius

lol embeer


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2005 Saab 92x Aero 5MT | The basic mods, Stage 2.04
1968 Dodge Charger 383 | WIP, restored almost everything but body work

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#10 2015-04-20 22:05:27

racerjim
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Re: Rear strut tower rust info?

Yuck


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SOLD August 2016:  2005 Saab 9-2x Aero 5-Speed, Cold, Premium, Arctic Silver
Her Car:  2013 Chevrolet Equinox LTZ

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#11 2015-04-21 00:44:36

d4rkv
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From: Chester County, PA
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Re: Rear strut tower rust info?

Now I don't want to take my interior out to put in a new carpet and insulation. Since my car only spent three years up in Burlington, Vermont I hope I won't find anything like this.   neutral  hmm


2014 VW CC Sport w/ AFS - Night Blue - so far reliable on my 80mile commute
2007 Cannondale Scalpel 3 - minty w/ upgrades
2005 Saab 9-2x Linear - Satin Gray - unregistered/ stored away, afraid to check rear strut towers
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#12 2015-04-21 08:21:56

Scargo
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Re: Rear strut tower rust info?

Gonna have to inspect mine.  Running a bit of fear... eek


1995.5 Audi //S6, Black/Ecru; MRC Stage 2, Eibach/Bilstein, RS2 BBK, HID's, Eurotails
2005 Saab 9-2X Aero Satin Grey; Cobb STX tune/Cobb 25 mm FSB, 22mm solid adj RSB/H6 upgrade/Noltec Camber Plates/STI Pinks, Koni Inserts/Whiteline Rear Stress Bar/Izixhood/Stromung DP, Crucial HF Kitty, STi catback, Hella MicroDE fogs, color keyed/polished roof rails.

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#13 2015-04-21 09:24:35

krazykarguy
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Re: Rear strut tower rust info?

It looks far worse on the LH side than it really is. I will sand most of it off and cover it with POR-15, which is already in order. The RH side is the problem side - there is a hole in the inner panel about 1/4" in diameter. Thankfully, the car did not have to spend last winter up north, which likely helped to curb the spread of the rust.

Every car I have ever owned has gotten rusty to some degree, this car is no different. I am very much looking forward to owning a car in the south, as rust is a non-issue.

As others have posted in NASIOC, the root cause of the problem is a lack of a seal on the bolts that the seatback latches to. Capillary action pulls the water into the cabin where it soaks into the foam under layer and sets against the relatively unprotected inner body panel. My pictures are the result.

I will continue to post pics as I fix the problem here in this thread.


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2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#14 2015-04-21 09:34:24

Skorpion25i
Just a dumb 20-somethin' year old
From: Epping, NH
Registered: 2013-10-12
User Number: 11520
Posts: 2022

Re: Rear strut tower rust info?

I was having a hard time figuring out where this is. I'm going to have to inspect mine... hopefully it's as simple as a little wire brush and some POR. Here's to wishing  embeer


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#15 2015-04-21 10:22:33

jgreen19
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From: Connecticut
Registered: 2013-11-02
User Number: 12072
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Re: Rear strut tower rust info?

Skorpion25i wrote:

I was having a hard time figuring out where this is. I'm going to have to inspect mine... hopefully it's as simple as a little wire brush and some POR. Here's to wishing  embeer

Me too. Getting a little worried. Krazy any chance you can take a picture further zoomed out to give a little perspective?


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#16 2015-04-21 10:27:58

Scargo
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Re: Rear strut tower rust info?

arrow-uparrow-up arrow-up   Unfortunately, if you read thru the NASIOC thread, a wirebrush and POR15 won't do it, it's rusting from the inside of a doubled panel that Subaru "intelligently" drilled thru for the upper seat brackets then failed to seal well enough to survive around a decade of flexing.  Really requires a cut/weld replacement. Pisses me off.


1995.5 Audi //S6, Black/Ecru; MRC Stage 2, Eibach/Bilstein, RS2 BBK, HID's, Eurotails
2005 Saab 9-2X Aero Satin Grey; Cobb STX tune/Cobb 25 mm FSB, 22mm solid adj RSB/H6 upgrade/Noltec Camber Plates/STI Pinks, Koni Inserts/Whiteline Rear Stress Bar/Izixhood/Stromung DP, Crucial HF Kitty, STi catback, Hella MicroDE fogs, color keyed/polished roof rails.

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#17 2015-04-21 10:47:33

jgreen19
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From: Connecticut
Registered: 2013-11-02
User Number: 12072
Posts: 188

Re: Rear strut tower rust info?

Scargo wrote:

arrow-uparrow-up arrow-up   Unfortunately, if you read thru the NASIOC thread, a wirebrush and POR15 won't do it, it's rusting from the inside of a doubled panel that Subaru "intelligently" drilled thru for the upper seat brackets then failed to seal well enough to survive around a decade of flexing.  Really requires a cut/weld replacement. Pisses me off.

Noo.....   banghead


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#18 2015-04-21 13:15:51

krazykarguy
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Re: Rear strut tower rust info?

For a 141k mile car(as is my case), the simple repair option should be sufficient, especially if the environmental factors that contributed to the problem have been removed. I plan on getting as much of it off the inner surface as I can, then using a 'rust converter' fluid in the panel. Afterwards, I will use the POR-15 everywhere possible. I am getting a quart of the stuff, and it 'flows' pretty well.

Weld in replacement is not a feasible option, although you can do a really ugly job since it will be covered up by the interior bits.


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2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#19 2015-04-21 13:23:34

krazykarguy
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Re: Rear strut tower rust info?

As info, you have to take everything from the rear cushions back to get the carpeted side panels out...

1.) remove rear seat cushion
2.) remove trunk floor bits and jack
3.) remove rear seat back (hint: unbolt cushions from center hinge)
4.) remove rear plastics around rear 1/4 windows
5.) remove side carpets
6.) remove foam behind carpets. The square clips were such a bitch to remove I left them in and gently removed the foam around/off them.


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#20 2015-04-21 16:25:37

Scargo
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Re: Rear strut tower rust info?

My right side has tell tail drips by the lower cushion.  This looks like such a PITA.  banghead


1995.5 Audi //S6, Black/Ecru; MRC Stage 2, Eibach/Bilstein, RS2 BBK, HID's, Eurotails
2005 Saab 9-2X Aero Satin Grey; Cobb STX tune/Cobb 25 mm FSB, 22mm solid adj RSB/H6 upgrade/Noltec Camber Plates/STI Pinks, Koni Inserts/Whiteline Rear Stress Bar/Izixhood/Stromung DP, Crucial HF Kitty, STi catback, Hella MicroDE fogs, color keyed/polished roof rails.

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#21 2015-04-21 17:09:36

itsnotmeitsyou
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From: San Antonio, Texas
Registered: 2011-07-31
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Re: Rear strut tower rust info?

Good time to change out the fuel filter smile


2005 Saab 9-2x Aero:  More than you've had done to your car.
2015 Forester XT 'TS' clone

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#22 2015-04-21 17:40:15

krazykarguy
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Re: Rear strut tower rust info?

Scargo wrote:

My right side has tell tail drips by the lower cushion.  This looks like such a PITA.  banghead

Honestly, I had the whole interior out in 45 minutes...

A clip removal tool (instead of a flat-bladed screwdriver and needlenose pliers) would have made it quicker. Otherwise, the only tools needed are a #2 philips screwdriver, and 10mm, 12mm, and 14mm sockets and wrenches.


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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#23 2015-04-21 19:31:35

tonka92x
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Re: Rear strut tower rust info?

Borrowed a borescope and took a look down behind the interior panel.  Yup, plenty of rust in there mad  Anyone report this on NHTSA's website yet?  A seatback latch failing could kill a rear seat passenger in an accident.  At the very minimum the rust holes could allow exhaust gases to enter the passenger compartment.

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#24 2015-04-21 19:50:43

Scargo
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From: Hancock, NY
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Re: Rear strut tower rust info?

krazykarguy wrote:

Scargo wrote:

My right side has tell tail drips by the lower cushion.  This looks like such a PITA.  banghead

Honestly, I had the whole interior out in 45 minutes...

A clip removal tool (instead of a flat-bladed screwdriver and needlenose pliers) would have made it quicker. Otherwise, the only tools needed are a #2 philips screwdriver, and 10mm, 12mm, and 14mm sockets and wrenches.

It's still not necessarily pleasant out up north here...  But you've forgotten all of that stuff already  biggrin

And it's a PITA b/c I have to do something I shouldn't have to do...


1995.5 Audi //S6, Black/Ecru; MRC Stage 2, Eibach/Bilstein, RS2 BBK, HID's, Eurotails
2005 Saab 9-2X Aero Satin Grey; Cobb STX tune/Cobb 25 mm FSB, 22mm solid adj RSB/H6 upgrade/Noltec Camber Plates/STI Pinks, Koni Inserts/Whiteline Rear Stress Bar/Izixhood/Stromung DP, Crucial HF Kitty, STi catback, Hella MicroDE fogs, color keyed/polished roof rails.

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#25 2015-05-02 22:02:29

krazykarguy
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Re: Rear strut tower rust info?

So I've been quite busy lately (including a business trip to Mexico last week) so working on this has taken a back burner, until today. I got my POR-15 from Amazon for $45 shipped for a quart (Prime FTW).

I got out my collection of wire wheels and my cordless Dewalt drill and went nuts. Everything in the pics below has one coat of POR-15, and will eventually have 4. POR-15 flows really well, and I think that I was able to fill in most of the holes.

I started on the minor rust on the hatch corner:
http://i934.photobucket.com/albums/ad184/krazykarguy/FDCD3BAF-97C8-4A5E-8ED5-761AD0787B05_zpsp52o3qxd.jpg

I then did the spare tire well:
http://i934.photobucket.com/albums/ad184/krazykarguy/78208371-3CAA-4C83-819B-48C4224765D7_zpsnwxii2an.jpg

Then some minor cover up on the back side of the LH strut tower:
http://i934.photobucket.com/albums/ad184/krazykarguy/F2CCA2A1-9092-4D20-BD5C-4F6441E27D86_zpszp2uwagv.jpg

This is the front side of the LH strut tower. After cleaning it with the wire-wheel, it was clear that there was a lot of what looked like rust above was really just rust staining. Brake cleaner took a bunch of it off. Most of the rust was relatively minor and none of the inner panel (under the latch) was not significant. I also went nuts with the POR-15 on this side because there did not appear to be any black paint on it (reference the above pics).
http://i934.photobucket.com/albums/ad184/krazykarguy/D3170ACE-DF5B-49D9-AC30-4F51EFB1E6DF_zpsqtudzzbk.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/CCB8BE6D-AB6C-4FEE-80F3-E43371B0E7F4_zpsbxh99s4x.jpg

Then I got to the right side. It's clearly the worse of the two sides, but oddly, the rust was in a place that I have not seen on any other thread. After cleaning with the wire wheel, a hole the size of a quarter opened up, and two other holes appeared, both smaller than the other.
http://i934.photobucket.com/albums/ad184/krazykarguy/EB1B28DE-69D1-470D-B0AA-477845D40517_zpsq5dg3ba3.jpg
http://i934.photobucket.com/albums/ad184/krazykarguy/7D7CAA72-3854-4AC8-A6C4-8000C49568CB_zpsyzfqbyna.jpg

Unfortunately, the pain continues. I found some more rust above the RH tail light...
http://i934.photobucket.com/albums/ad184/krazykarguy/23E0D753-6F1D-4D94-A347-B2FBBEB212CD_zpsccixjula.jpg

Last edited by krazykarguy (2015-05-02 22:04:35)


2005 Aero 5MT
2014 Ford Mustang GT Premium 6MT - Sterling Gray Metallic

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