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Mazda Protege Rust Problems

31 messages,  Last post on Nov 15, 2009 at 6:57 PM

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What is this discussion about? Mazda Protege, Mazda Protege5, Auto Body, Paint, Sedan, Wagon

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#1 of 31 Mazda Protege Rust Problems by icvci May 19, 2008 (12:57 pm)
After noticing rust on my 2003 Mazda Protege 5 I did some searching and discovered that rust is really a problem on these cars. I think we need to have a place that everyone can voice their disgust.   On my car, the paint has completely eroded and there's bare metal in front of both rear wheels just above the lower trim. There's a dime-sized bubble on my roof. And I've got rust bubbling on the window frames on both the passenger and drivers side rear windows. (Those spots were visible summer of 2007.)   Mazda needs to do something about this, a car built in 2003 shouldn't be rusting away after 5 years. Replies to this message: rminnj (Apr 08, 2009 10:34 am) devilishangel (Sep 17, 2009 10:21 am) autonomous (Sep 17, 2009 10:55 am)
#2 of 31 Rust 2002 Protege 5 by zoom_oh_2002p5 May 25, 2008 (8:01 pm)
I had rust at 40,000 miles on my Protege5. Just behind the passenger side rear wheel well. The leading and narrow edge of the lower panel. I had a body shop do both sides at that location and touch up some rust on the rear door panels. At 60,000 miles I have rust on the passenger side above the panel that had rust before. I have rust developing at the seams above the wheel well in the engine compartment.   I am very upset about this, because it could keep me from driving this engineering gem for 200,000 miles.   Toyota Camry's have a chronic and premature rust problem in the same place, just behind the rear wheels where the body panels come together.   Rust starts where the steel feathers to its thinnest edge anywhere in the car. Take the metal back so another part of the car has a thinner edge, and the rust will show up at the new location first.   Toyota did a classic quality deployment study to actually set quality specs for rust. They did this by setting the specification for the thinnest dimension for steel on the lower part of the car. Look for areas in the sheet metal where the sheet metal is feathered to a knife edge and may have a ragged look. That's where the rust will usually start.   With the winning design and technical ZOOM team at Mazda I hope this rust issue gets addressed quickly, and if there is a technical solution for those owners who are disappointed with the performance (rust) of the vehicles they currently own, I hope the owners will be notified by Mazda of the solution.   There are specialized rust arrestors (not just a paint coverup) that actually convert rust to an inert compound and stop further rust. (Krylon-Duplicolor-"Rust Tough' -Sherwin-Williams). At one time I was marketing manager for Krylon Rust Tough from S-W, and handled marketing for Krylon and Duplicolor. You can find Duplicolor in most automotive departments and auto parts retailers. You can find Krylon in many parts stores as well as major hardware and building and lumber supply retailers.   Find the detail shop who does the touch up detailing for your local car auctions and you will find a shop that knows what they are doing with this problem. I was very happy with the work done by my body shop. I have not had a recurrence of rust in the 40,000 mile repair.   Good luck with the rust solution. I will continue to research and explore this issue, and report here what I end up doing with my second bout with rust, and with the rust problem on top of the wheel wells at the seams, in the engine compartment.   ZoomOH
#3 of 31 Re: Mazda Protege Rust Problems (shame on Mazda) by rminnj Apr 08, 2009 (10:34 am)
Replying to: icvci (May 19, 2008 12:57 pm) I just wanted to reply to this thread a year after to voice an angry ME TOO! Our 2002 Protege5 started rusting at about 40000 miles in odd places with paint bubbles. Mazda would do nothing. Now with 100K miles on the car and years later it is rusting everywhere..   - In front of both rear wheel wells (the side molding worn down the paint and the rust has eatenthe entire panel away....both sides.   - The very top of both rear wheel wells...the paint has bubbled out and is eating vertically upward. Mazda says a stone must had it direectly there (both sides).   - Where the rear bumper meets the rear wheel well. Again, Mazda says a stone must have done it.. (both sides).   - Right under the word Protege 5 in the middle of the hatchback the rust has bubbled almost all the way up to the window.. Never a scratch or dent there..it started under the word/eblem.   -Under all 4 doors ..the weld seal of the door panel has failed and seperated and rust is visible.   - Entire undercarriage of the car. The undercoating has failed and there is rust visible everywhere. Car is 6 years old and we're afraid the floor boards may give out.   - All 4 alloy wheels..the paint on them bubbled/corroded up on all edges.   Except for the bearings and suspension the car has been quite reliable. Too bad because any savings are negated because the body is beyond repair. It's like we purchased an old Honda or Fiat from the 1970's and there is no galvanized metal anywhere on the car.   When I see those shiny new Mazdas and read the good reviews I get upset...to think that even all the new Mazda 3's will be rusting in the rear wheel wells in a few years. A real shame, the car has been reliable but we could never buy another one.
#9 of 31 02 protege 5 w 40k miles! by 02mazda Jun 29, 2009 (2:46 am)
I also am experiencing the bubbling of paint behind passenger door on leading edge of wheel well. I garage this car 75% of the year. (Vespas need Mazda side in summer). I wash it frequently. Myself. W Turtle Wax Auto Wash. I wax it 3x/year. I baby this car. I love this car. Have seen a silver 02/03 model in town w lots of rust on it. Reason I checked mine out. Has anyone had any luck w Mazda on this? It was not a cheap car. Stickered close to $20k w the options I got. I am hesitant to buy another one.
#10 of 31 02 showing rust:( by 02mazda Jul 16, 2009 (4:35 am)
Got a song & dance from local dealer & regional rep about Mazda not being responsible for this on account of climate. I rephrased the response by saying "What you are telling me is that Mazda sells cars in markets that they are not built to handle?" No response. I like the CX7, but would not even look another Mazda if this is company policy. Caveat emptor, big time, I guess. I hope Mazda does check these boards out. My 02 Subaru has no rust on it. Had a bad head gasket 53k miles. Yes, out of warrany. Many others had this problem. After some wrangling, online w Cherry Hill NJ HQ, they decided to cover it. I inititally requested a 50/50 solution as the car did have 53k miles on it. They covered it all, a non Subie shop as we have no dealership in my city. Mazda, do the right thing. Cover these cars! Overall the car has been gr8. No other problems. A shame they have chosen this course of action (inaction!) Replies to this message: autonomous (Jul 16, 2009 6:54 am)

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