Last post on Dec 24, 2012 at 11:59 AM
You are in the Mazda Protege
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Mazda Protege, Mazda Protege5, Auto Body, Paint, Sedan, Wagon
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.
#3 of 100 Re: Mazda Protege Rust Problems (shame on Mazda)
Apr 08, 2009 (10:34 am)
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 100 02 protege 5 w 40k miles!
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 100 02 showing rust:(
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!)
#11 of 100 Re: 02 showing rust:( [02mazda]
Jul 16, 2009 (6:54 am)
would not even look another Mazda if this is company policy. Caveat emptor
I hear you.
Actually I'm getting obsessed! As I walk by vehicles I glance at the state of the body and look for rust ... sure enough, I see other Proteges with the familiar pattern of rust around the rear wheel wells. This does not inspire confidence in the brand, especially if you know you have done everything reasonable to maintain the vehicle (e.g. rustproofing). I believe the problem partially involves the manufacturing process and partially customer relations. If auto manufacturers want to survive beyond the initial sale, they should recognize that they have a responsibility to their customers to maintain fair value in their investment.
In a related vein, Mazda had announced earlier this summer a new painting process to reduce the impact on the environment. Let's hope Mazda is looking for other ways of improving their processes to respond to customer issues.