2008 Wrangler Rust Issues anyone?

Asked by Mar 04, 2008 at 11:47 PM about the 2008 Jeep Wrangler

Question type: Maintenance & Repair

I bought a new 2008 Wrangler Unlimited (Yellow) a little over two months ago.  It now has 2,302 miles on it and am noticing rust all over the exhaust pipes, muffler, driveshaft, and rear suspension.  I drove it to the dealer and I was told "That's Normal." I said $30,000 and in two months you call this normal? He said that warranty won't cover it and there is nothing I can do.  He said it is because I live in PA and drive it through the snow... but IT'S A JEEP!  Is anyone else having any problems like this? I also have a 2001 Audi with 110,000 on it now that I drive in Northern Michigan that has very little rust on it compared to my new 2 month year old Jeep. Any Suggestions? I already emailed Jeep a few days ago...no reponse yet. PLEASE HELP!

46 Answers

this is a normal thing,driving in rain ect,nothing to worry about.

1 out of 1 people think this is helpful.
305

the slight rust is cause by condesation on the undersides and its normal and eventually it will rust through but it will take many years

2 out of 2 people think this is helpful.
30

I am having the same problems. I bought a 2008 Jeep Wrangler in September and the muffler looks worse than my old Camaro's. I took it back and they suggested painting it black with grill paint. After much complaining, they agreed to put on a new muffler (painted). I hope this fixes the problem rather than masking it??? I'm also concerned with the rust on the door hinges. They shabbily cleaned it off once. However, they told me to expect it to come back and that I should grease the inside of the hinges. I love the Jeep. However, with it only being 8 months old and having 3,000 miles, I wonder how it's going to look in 2 years??? Let me know what happens with your's.

3 out of 3 people think this is helpful.
20

I have a 2008 two door that I bought in October with 7k on it right now. My muffler is covered in rust and looks tacky with a brand new Jeep. I also have a 2001 Jeep that my daughter drives, same muffler, way less rust. I think it's an issue with the new ones. The dealership won't acknowledge it being an issue. I understand it's not a problem to worry about, but I forked out a lot of money and the back of my 2008 vehicle looks like hell.

2 out of 2 people think this is helpful.

I also have a yellow 2008 four-door wrangler with rust on the muffler and door hinges. I spoke with someone at Jeep's warranty division who told me that should be covered for 5 years or 100,000 miles. It is body rust. The problem lies with the pin in the hinge. If that is a problem, perhaps Jeep needs to address the issue of the simple pin before they encounter class action law suits! I love my Jeep, but not the hassles I have been getting this week. I know many people with jeeps who have not had these problems. They own older jeeps. Maybe that is the problem. Cutting corners is not good. Another thing we noticed was that the roll cage is not completely painted. We were putting our soft top on this summer and pulled the padding back. SURPRISE! Not all yellow. What a load of crap.

have an 07 4 door i love. hinges rusted last year with about 15,000 miles so i called chrysler and they had to pay to get hinges repainted. again, this year with 32,000 miles, same problem so the dealer is repainting them one last time at no charge to me. looks like i will be putting on some stainless steel door hinges next year. they run around $250

30

I have a 2008 4 door Sahara. Bought it in September of '08. It has 8,000 miles and rust above every tire, on all the hinges, and around the bolts that are around the windshield. my muffler and exhaust are also looking awful with rust. brought it to dealer and they buffed out the hinges. for a $30,000 car this shouldnt be happening. any suggestions?

3 out of 3 people think this is helpful.

I have a 2008 4-door Jeep Sahara with 4,000 miles on it and my door hinges are rusting as well. I took it to the dealship I purchased it from and they told me to take it to a Jeep dealship with a body shop, explain the problem, they will take pictures and then send them to Chrysler to review. My response to them; "So.... in the mean time I just sit back and watch the rust go from the hinge pins to the hinges to the doors." I got the blank look. I had a 1998 Chevy Silverado Z71 pickup truck that never saw the inside of a garage, drove through all kinds of weather in Ohio, Michigan, Pennsylvania and Maryland, yet only had two little rust spots on the tailgate. That was with 196,000 miles on it. I think Chryler has a problem with their door hinges they really need to fix.

20

I have a 2007 Wrangler Unlimited that I bought brand new. My door hinges were all rusted after 5 months! They were fixed before the warranty was up. Now they are rusted again and I was told they won't do anything. It's not their fault. I guess it's mine somehow. I take good care of my Jeep. I've never been off-roading. I'm the mother of three young children. I thought I bought a new reliable vehicle. I bought an expensive piece of s---!There are more problems than that. Today I told customer service that I hope they file chapter 11, I hope the business goes under, and I'm wishing they all lose their jobs because they don't stand behind their product. Can you feel my level of frustration???

2 out of 2 people think this is helpful.
15

I bought mine last year, exactly the same as you, and we have the same problem. The best thing you can do is to oil treat your Jeep . The pipe are very cheap but either if they look rusted, they last for long. I had the same reaction and it's normal,like you said ,for a 30,000 $ truck,it's kinda pissing off !!!!

1 out of 1 people think this is helpful.
55

I see the surface rust on the drive shafts, and a little on the seams of the muffler, not to much to worry about. What I have to agree with is the person who commented on the hinges. I saw the same thing and though how ridiculous it looks to have a jeep that is 1 year old and corroded hinges. I am disappointed on that fact. Other than that I have not seen the rust as bad as other explained on the muffler. My suggestion is to start saving now for a a low restriction exhaust to go the the High flow intake I know everyone will probably put on soon.... :-)

5

it is a normal thing for jeeps to rust but what u can do to stop the rust on vitle parts of the jeep is use the spray insulation foam u get in cans and fill the frame with it so water cant get in and rust it out from the inside outt and what u can also do is get this stuff called por 15 and cote what is already rusty and whats not and it wil stop the spread of rust

55

2007 jeep wrangler JK sahara unlimited rusting muffler >spent $500.00 on a gibson stainless steel dual performance muffler problem solved,sounds awsome too!

15

Yeah salt and Metal dont mix very well. I spend laborious hours at a 4x4 shop in the BX NY (JP'S Crawler and 4x4), I own several jeeps all older.. 81cj8, 83cj8,87yj, 89yj, 97tj, 73 international scout.. anyhoo they all get their frame Hercalined or some sort or rust frame sealing... roll it on in some dirty clothes. and it will help prevent water/oxygen and salt from getting on the frame.. From years of looking at cars/trucks dirt and grime can be lifesavers as rust preventative..so dont be a clean freak, unless youve taken preventative measures. You know the snow is gonna touch the frame!

1 out of 1 people think this is helpful.
25

Rust never sleeps

1 out of 1 people think this is helpful.
85

Rust on non-stainless exhaust parts is pretty much standard on all vehicles. The corrosive undercarriage environment is only exacerbated by the heat of the exhaust (heat speeds up chemical reactions). my suggestion is to get some POR-15 paint and some por15 thinner and put a few thinned out coats on the rusted parts. The rust you're talking about is mostly superficial, so time isn't critical. Do it sometime in the summer so it has plenty of drying time before winter. The Rusty OEM exhaust on my 03 TJ is still going strong after all these years. i Painted the driveshafts a year ago (thinned out coats, the por 15 penetrates into the rust). As for the dude who said to fill the frame with sealing foam?- DON"T DO THAT!!! That stuff acts like a big sponge and will only hold water and salt in your frame and rot it!!! The jeep should be put on a hill and the frame hosed out every spring. I also use LPS spray galvanize on any bare metal or rust. The stuff works awesome.... not on exhaust though. Remember- there's a big difference between a Jeep and an Audi.

4 out of 4 people think this is helpful.
85

As for the rusted hinges- if it's the hinge pin itself, i'd recommend some Never Seize. Take the door off and put a light but even coat on the pin. I'd totally Agree with being pissed off about rust on painted surfaces and around bolts and such on such a young jeep. Perhaps the Quality has gone down since I bought mine. Electrical issues were the norm when i bought mine. I seriously think you need to be a mechanic to successfully own a Jeep!

2 out of 2 people think this is helpful.
55

Here here on the mechanic part, but isn't that the fun of a Jeep, because they are so easy to work on. Chrysler has never been high on the list in quality. American motor either, but as sophisticated as cars are now its seems they could figure out how to make a car that doesn't rust in one year....

10

Bought a custom ordered 2008 Wrangler, garage kept every day and less than 3M miles and all the exhaust and joints are rusted. Have read many comments from owners and only a few with months of arguing had a dealer help out. I was told by one service person it was due to cheaper exhausts used, even though Chrysler will deny. I will spend $600 and put on new exhaust, that is under warranty. This will be the last US car I buy, have lost all faith. My 04 Lexus sits outside all winter every year, no rust!

1 out of 1 people think this is helpful.

I have the same problem; will a lawyer take a class action suit while they are in chapter 11; ever other car on the road does not have this problem; there is something worng & the should fix or replace the jeep; thank god mine is leased on tey can have it back next year..

6,675

its a common problem with jeep wranglers. they always rust. they always have. you should have researched that before buying one. now had you bought a toyota or mazda from ten or fifteen years ago you should expect those to rust out also. dont stop buying american cars because a jeep wrangler got rust. its a commonly known problem with them. hence the only reason i didnt buy one.

2 out of 2 people think this is helpful.
10

I have the exact same problem! I had problems with shaking/vibrating in the steering column (which of course they say is "normal,") and then within 5 months, my whole entire Jeep Wrangler Unlimited 2008 COMPLETELY rusted out. They have given me the run around and said it is "normal." I won't stand for it! Anyone reading this post that wants to email me their issue/contact info. with rusting or steering problems in the Jeep Wranger Unlimited 2008 ( Sahara, other 2008 models etc..), I will gladly take it to a class action lawyer when there are enough of us, and see if anyone is interested in taking on the case. I am continuing to move forward with this legally, and I will not back down until this matter is resolved. Seems like too many people to just ignore. Email me at jencme35@yahoo.com with your rust issues and your contact info. and let's see if someone will accept this as a class action suit. Until that time, I will continue dealing with my own Jeep under the lemon law. Don't back down- continue your fight! Backing down is just what they attempt to drive you in to doing. Go and seek legal council! As far as comments about Jeeps always rusting, that is not accurate. I was a Jeep owner for years in the rain, sleet and snow and NEVER had any rust on my YJ! Nonsense!

1 out of 1 people think this is helpful.

Recall ID # 08V202000 - SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS - Hide Details Recall Date: MAY 06, 2008 Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS Model Affected: WRANGLER Potential Units Affected: 1709 Recall Date: MAY 06, 2008 Model Affected: 2008 JEEP WRANGLER Summary: CHRYSLER IS RECALLING 1,585 MY 2007-2008 JEEP WRANGLER, RIGHT HAND DRIVE ONLY, VEHICLES. SOME VEHICLES MAY HAVE INSUFFICIENT CLEARANCE BETWEEN THE STEERING INTERMEDIATE SHAFT AND REAR BRAKE TUBES. Consequence: PROLONGED BRAKE TUBE CONTACT COULD WEAR A HOLE IN THE TUBE AND CAUSE A PARTIAL BRAKE SYSTEM LOSS. THIS COULD CAUSE A CRASH WITHOUT WARNING. Remedy: DEALERS WILL INSTALL A REVISED BRAKE TUBE CLIP TO RETAIN THE TUBES, INSPECT THE BRAKE TUBES FOR DAMAGE DUE TO POTENTIAL CONTACT WITH THE STEERING INTERMEDIATE SHAFT, AND REPLACE THE BRAKE TUBES IF NECESSARY. THE RECALL BEGAN ON JUNE 30, 2008. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403. Potential Units Affected: 1709 Notes: CHRYSLER LLC H17

20

I have a 2007 Jeep Wrangler and have the same problem with the door hinges, the paint is all bubbled and rusting from underneath. I was told the undercarriage is so rusted that if I ever need to replace something like a u joint I'll probably have to replace the whole front end. Jeep has a 5 year corrosion warranty but my local dealer said he could not make that decision, it's is up to the Chrysler district manager. They had my Jeep for 41 days until the Chrysler rep came to look at it. He denied the claim saying it is "surface rust" and attributed it to "environmental causes" because I live on the Gulf Coast. The local service manager disagreed with him but he said there is nothing he can do. He feels I have a good case against them. Unfortunately I can't afford an attorney. There are a couple of things you can do. 1. File a complaint with the NHTSA division of the U.S. Dept. of Transportation. The more documented complaints they receive the better because it establishes a pattern. If there enough complaints they can force a recall. It is a lengthy process, but filing the complaint is quick and easy. 2 Contact your state's Attorney General. 3. Contact the Federal Trade Commission 4. File a complaint with the Better Business Bureau. You can file complaints with all these organizations online quickly and easily. I did it in under 1 hour. Again, the more documented complaints and negative publicity this gets, the better. Anyone up for a class action suit?

2 out of 2 people think this is helpful.

2007 4 dr Wrangler hinges are corroding under the paint on all doors as well as the suspension, exhaust, frame, bolts around windshield etc. Hood latches are almost white despite the $600.00 Simonize package. Driver's door had a knocking sound, dealer "fixed" it, door started popping open..adjusted it myself. My dealer was shut down in the gov't takeover so I have to find another. A florida car kept under cover 20 hrs a day? Come on!

i BOUGHT MY 2008 BRAND NEW AND PAID EXTRA FOR RUST PROTECTION HERE WE GO NOW REMEMBER I WASH MY JEEP 3 TIMES A WEEK AND ITS GARAGE KEEPT. DOOR HINGES RUST HOOD HINGES RUST HEAD LIGHT BENZELS RUS DOOR LATCHS RUST ANTENA REST SEAT BELTS RUSTED ANR THE SEATS PLEASE ALL MOUNTING BOLST RUST DRIVER SEAT FOAM DEFORMED AND METAL HITS YOU BUT. 16,000 MILES 2 YEARS OLD OVER 30000 $$ NOT HAPPY THIS IS MY 4TH JEEP AND BY FAR THE WORST MEETIN WITH A FACTORY REP FRIDAY AM LETS SEE WHAT THEY SAY

I have a 07 Jeep Wrangler 4 door and I have rusty hinges. The dealer repainted once and now it needs to be done again and the warranty has expired. I will be putting on black powder coated hinges in the spring. Chrysler should reimburse me for the cost of the new hinges. The rust started after having the jeep for 3 months. The rust reappeared again in 5 months after having them repainted. I was told that this would continue to happen as long as I take the doors off. The doors have never been removed. Go figure. This is the senc Chrysler product I have had that has had premature rust problems.

Well it is now 2010 and my brand new Jeep Wrangler is rusty, i've had it for two days and i decided to look inside the engine and there's thick rust on both sides, along the engine shaft and other spots. We dont get salty roads here in Australia. ..and the muffler looks like it's been sprayed with a protective coating so hopefully i wont have the same problem as the 2008 models. Anyway, just thought i should see if this was a common issue and it is. Im very disappointed and i cant wait till monday morning to call up Jeep and ask them WTF?

145

wow i have a 90yj with no rust on the body but if you go offroad alot the exhaust usally rust pretty quick and easy unless you put and affter market one on like flowmaster or somthin like that thats made for that abuse

1 out of 1 people think this is helpful.
20

Well well well it's June 2010 and I have the same problem, after just 3 days and I saw is totally covered by rust under the carriage, here a bit of pics to enjoy: http://picasaweb.google.it/pierbiondi/FotoRuggine02?authkey=Gv1sRgCMWBuJPvhrWhUA&feat=directlink Very disappointed by Jeep, or they explain or never Jeep again!

2 out of 2 people think this is helpful.

Don't put spray foam on your frame! Water will still find it's way in there and you will make it worst! Don't be so retarded! Rust Check or crown undercoating from day one is best solution. I seen a brand new Wrangler that had rust started on rear axle at the dealer.

5

warranty covers rust on the body and frame. the parts you listed have thick enough metal to last along time without rusting out (muffler being the thinnest and will rust out long before a drive shaft).. although it would be nice for them to be painted better (or even at all in the case of steering knuckles on the font axle).. only part i would be realy disappointed in would be the muffler as it shouldn't rust as fast as they are on the jk.. although its probable just noticed more because its so visible.

08 Wrangler. Rusted door hinges about a year after I bought mine new. Just recently called Chrysler Corp and requested a buy back and waiting to her with in 48hrs. My frame is rusted at all of the weld points. Any one with an 08 should check this out. Any one else out there with the same issue? My muffler system is also rusted. The frame bothers me more as the welds hold the frame together. My co worker also has an 08 with the same problem. I can even see a stress point that has rusted and is now cracking. I told Jeep I would keep my Wrangler until they are forced into a buy back. I had a Tacoma that Toyota bought back for the same problem and thought I would try a Jeep out. My mistake... I currently have open recalls and my gear box has a clear fluid leaking from it that they tried to fix before. I was told they will not honor any warranty or recall repairs until I hear from the buy back department. Way to honor your product... not to mention that I am a smoker and there is no ashtray and my gas tank shoots out gas if you top it off or the tank is full. But they wont honor that recall until I hear back. I would love to see my Jeep coasting down the road in flames at this point.

People who think that this is normal should think again. I have an 08 Wrangler with rusted door hinges and muffler system. I have also noticed that my frame has rusted at all of the weld points. I called Chrysler and am waiting to hear from the buy back dept. Had a Tacoma that was bought back for the same reason... All 08 owners should check the frame for rust so and hopefully Chrysler will finally open the recall. The rep was quick to get me off the phone and over to the buy back dept as I am almost certain they are receiving numerous complaints. I have even noticed an area that has rusted and is now cracking. This is also out side of the brake recall and the gas tank that shoots out gas when its topped off or full. I was told they will not honor any warranty repairs or recalls until I hear from the buy back dept. Hopefully nothing goes wrong till then. Way to honor your product..... If I wanted to deal with a rust bucket I would have restored an old one that costs next to nothing. Hopefully I can say good bye to Chrysler for ever !!!

6,675

when you say "top it off" do you mean add more gas after the pump shuts off the first time? if so im betting the manual tells you not to top of the gas tank. i know my 300C from chrysler told me not to do that. if not and this is happening its just weird. and no cars come standard with ash trays anymore. none. they have to be special ordered.

2 out of 2 people think this is helpful.
40

To all the folks having problems with their brand new jeeps rusting out, or more specifically, to all those considering laying down $30K for a new jeep: 1) Put the $30K in a savings account where it will draw at least a tiny bit of interest 2) Shop around for frame-off reconditioned jeep with model year 1986 or under. Resist going older than '77. 3) Expect to pay $8K to 15K for a really good rebuilt jeep. Insist on "frame-off" work with engine, tranny and transfer case totally rebuilt. The jeep frame should have been dipped prior to reassembly. 4) Enjoy the jeep, as you have REAL jeep before Chrystler turned them into plastic trash. As things go wrong--they will--dip into your savings account and make the repairs. 5) If you take care of your machine, your jeep AND your original money pot will last longer than you will. In sum, don't buy a jeep manufactured after 1986.

4 out of 4 people think this is helpful.
145

what kind of rust are we talking about hear pic would help! your stock exhaust should be stainless steal which will discolor but should last a long time before you would ever need to replace it!

Judging from my experience (jeep wrangler 2002 with 80K mile) rusted underneath to the extent to loose brake. Replacement cost $750 estimate DO NOT BUY JEEP it is not only an inferior product of a twice bankrupted corporation, but it is a MORTAL threat to the driving public. The Jeep Wrangler I have has all the earmark of a failed company. I had to replace the clutch @ 60K because the spring in it broke – an other $800 unnecessary expense. Not to mention small issues like leak rain all over even with hard top, piling paint on the body after just 2-3 years, failing electrical wiring.

45

If you take your jeep through mud, then the mud sits on the exhaust and the water inside the mud rusts the exhaust. That and your jeep may have not come with stainless steel pipes.

i have 2008 unlimited 4x4 purchased in the modle year living in Massachusetts. i noticed the same thing. The good news is it has progressed to a real problem, face it , it's the uindercarrige of the vehicle and it's not stainless steel. what i am pissed about is i have noticed bubbling of paint on one of my exterior door hinges. now thats a problem.

10

Use Petroleum Jelly for small parts that you can removed and where ever else you see rust starting coming up. This product has more consistency than anything else. Would stay stick even after applaying direct water. I also very useful in roof gaskets and doors "likely aplication" dont spend gallons...!!! Jeep is not a fast sport car. To me is the best off road and cityt streets. Dont tried to go from 0-60 in 5 seconds. Dont Complain, Enjoy the real use of a "JEEP" Good Luck!

1 out of 1 people think this is helpful.

I live in the U.K. and bought a new Wrangler JK in 07 it is kept garaged and done few miles as I use another car. My door hinges are rusting, this is due to water collecting in the door mirror after washing etc and it slowly runs down over the hinges and gets behind. Jeep looked at it and said not covered....funny how they have changed the mirror design now!

Never had problem with rust on my 2007 wrangler but with my 2006 i had rust issue and i was living in NY even the wheel was rust but i have found a solution to underbody issue spray with Pure rubber compound on everthing underbody it will stop the rust issue for good and far as the door hinges most rust is starting inside the hinges not on the outside yes you should replace it with stainless steel to prevent this issue ruddering the underbody only cost me $150 and 20 hours of my time == Far less problem and headache with Jeep dealer

Have a 2007 jeep rusted in the back muffler, frame looks awful. Never take it off road. Take good care of it. This should be with a 6 year old vehicle, looks like a 20 year old car underneath

Just wondering... It's June 2014 and still having corrosive rust on both wheel axels, muffler, tie rod, door hinges, etc. I realize that this 08 Wrangler is 6 years old but this rust is extensive! I also own a 2005 Jeep Liberty and it shows very little surface rust throughout the under carriage. Does anyone PLEASE have any current information on warranty coverage, buy back, recall or class action suit regarding this problem? I would very much appreciate any feedback. Thanks.

5

On ships, and in water heaters, they attach anode's to the body. This is usually a piece of zinc. It rusts instead of the steel. Has anybody ever tried this on their car body or muffler? http://www.boatzincs.com/OMC980756.html?gclid=Cj0KEQjwkv-rBRDwoMLav-2l9KIBEiQAUTkDU0d_iNJVJf9EfKU0i9RxE9kU5sycxWASrF7DrVRMqj0aAgRT8P8HAQ https://en.wikipedia.org/?title=Anode

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