Rusting doors on 2002 S500

I own a 2002, S500 with 85K miles on it. Since I have had it, I have had to replece the main instrument cluster (on warranty) and most recently the alternator last December. When the alternator quit on a trip down south, I had to have the vehicle towed on a ramp truck. I noticed when the car was on the truck, that both front doors were severly rusted at the bottoms for their entire length. It should be noted that the car doesn't get much exposure to snow or salt treated roads.

I was able to locate a shop that did body work (sanding, repainting and new trim molding) for about $560. Upon completion of the job, the guy told me that the trim that is located at the bottom of both doors is allowing water to get inside the door itself and cause the rust. He told me that I was lucky in the sense that the rust hadn't yet rusted completely through the door, otherwise I would have to have the entire door(s) replaced. He went on to show me that both rear doors are showing signs of rust also, and advised me to have them repaired when I got home.

I would advise readers to check the bottoms of their doors for signs of early rusting and address the problem as soon as possible.

When I purchased the car in 2005 with 43K miles on it, I expected the vehicle to be reliable, but I find myself very disappointed with the Mercedes product I am very interested if this rusting problem is common to other owners of 2002 S500 owners, or am I just unlucky?

Yep,
Widespread problem.
Lack of adequate process control in the factory. Some vehicles exhibit a problem, others are fine.
In the UK MB UK tell the customer that it is because SALT is used on the roads and the owner fails to wash the car regularly enough!!
However despite my own best efforts I gave up with MB UK. They accepted my reasoning but basically said TOUGH!. In 2000 the vehicle only had 1 year warranty.
As a consequence of this disastrous episode in MB history a 30 year warranty is now part of the UK Warranty programme. However when you understand how the promise works its not what it seems...but is anything nowadays!
Stuart.

They had a TSB on this model as far as rust build-up in doors.
 
take care,
-mar-

Hi,

Got a copy of the S Class TSB please?
Stuart

Sure...but don't show it to MBUSA or UK...oops!!!!!!!!!
 
Campaign No. 2005030003 April 2005
Revised May 2005

FILE:
SERVICE:
GROUP 00 OF SERVICE INFORMATION BINDER

PARTS:
GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

TO: ALL MERCEDES-BENZ CENTERS
SUBJECT:
MODELS 203/209/220
SEAL LOWER STRIP ON DOORS

This revised Service Campaign bulletin 2005030003 supercedes previously issued Service Campaign bulletin 2005030003 released in April 2005. It contains updated warranty information to allow the repair of noticeable corrosion under certain conditions. Please destroy all previous Service Campaign bulletin versions.
This Service Campaign has been initiated because DCAG has determined that on the affected vehicles (see VIN range) the seal at the bottom of the doors may be insufficient and requires additional sealing material.
Please review the Effective Serial Number chart and if necessary repair the subject vehicles during the vehicle's next service.
Prior to performing this Service Campaign:




^
Please check VMI to insure the vehicle is involved and to determine if the vehicle has been previously repaired.


^
Please review the entire Service Campaign bulletin.

Approximately 212,885 vehicles are affected.

Hi,

So what is the affected VIN range? / model years? 212k vehicles!!

Stuart.

I don't want to get in trouble coz some of these are "classified" information...
 
 
take care,
-mar-

"When the alternator quit on a trip down south" Funny because last summer on my drive down to my place in Florida the same thing happined on my 2002 E320. Well it didnt die the warning light on the screen in red appeared and I knew it wouldnt make it back to New York.

Replace the voltage regulator.  99% of the time it the brushes that wears out, and it's cheaper...
 
take care,
-mar-