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I fully agree that this is a manufacturing defect to the max. The defect, is, an engineering failure and like mentioned this can happen to many vehicles that live on salted roads. Salt on roads should be stopped. Not only is it bad for vehicles on the roads but the run off into the fresh water streams and rivers as well. Then the steel rebar in bridges and over passes. They all need to save the salt for the dinner table only. The defect ? Many fold ! Horrible paint that is used, and in critical rust areas wrong or no special treatments used, or just plain wrong materials that are used. Also many times the unit body frames and suspension parts can be boxed assembly's that have holes all around them to let the salt water ingress, so they pretty much rust from the inside out. Sorry Nissan all this rusting is on you.
Cutting corners and building sub par vehicles for a kings ransom price is the name of all the auto makers game. The part I like is the years of lies when they say they dip the bodies in a rust preventative, I have a 1957 salesman book saying similar, and we know how bad some of those years can be as a pile of rust.
Like I say someone can be looking all day at the bottom of some of these vehicles and never see the problem, if the rusting is all inside the box sections, out of sight out of mind.
With proper treatment inside those sections and sealing all holes and seams so there is zero ingress of water etc.and all welded seams painted with primer before welding this stuff could be almost eliminated as a problem. But most people are more worried about a big fancy screen and a ton of electronics rather than a rust free vehicle.

I reread the very first post on this topic.
They are wrong, it is a manufacturing defect. Just as I pointed out.
Those parts were not protected in the hidden areas if done correctly there would be no rust inside. And if done correctly on the outside the only thing that would have caused rust would be manually removing the paint and or protective coating.
So the metal was not protected during the manufacturing process. If the latex paint they use was applied directly to steel that could aid in starting a rusting issue.
 

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The type of steel will be good old normal sheet steel used in most all body panels.
A stainless steel could be used in area's prone to rust if they wanted to, it can be welded to normal mild steel as well.
Just using the correct treatment during manufacture would be a huge help. Simply treating the areas with a phosphoric acid, before using a high quality epoxy paint would help prevent the rusting. Then applying a quality seam sealer to make sure there could be no ingress of water into the lapped seams that are left after spot welding, the panels together. And of course using multiple coats of "quality" 2 part paint over all that as well. Just like the old 50's cars and trucks maybe they dip them into a vat of rust instead. :(
And to add do this same treatment to all the internal areas of the unibody frame as well. The acid treatment has to be done after welding is done. Painting internally could be done like this.
 

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Maybe this is only a suspension rust out failure. But there are many other instances of unibody frame rust outs as well. I would bet this car may have a problem with that in some area, since this was as bad as it is. Everything I have said still applies. If it is such a know problem then maybe they should have used stainless steel, if they don't know how to preserve the steel they did use.
Hasn't this been happening on Muranos since the beginning? No bubbles have been burst, just another bubble created.
 

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Please keep us informed on the findings of the inspection. I hope they do an indepth inspection of other areas that could be prone to rusting as well as the original problem. Make sure they explain the reason for that rust out (poor anti rust treatment / inferior materials etc.) and also have them explain what would have prevented that from occurring. There is no excuse for that happening period. Maybe those components should be immersed in a zinc plating solution and then painted, I don't know for sure. I do know those parts should be treated like they are to be used in a marine environment, the question is how would they be made or protected if they were to be used on an aircraft carrier deck environment?

All those cars should have a safety recall right now. And no Nissan crying about it being an old (10 years) car. There are thousands of aircraft flying that are many times older than that. When there is a problem on an aircraft a fix is done. If these car makers don't want expensive law suits or recalls, then just simply do it the correct way the first time. When will they learn?
Like others say this is a dealer problem, and it is also a manufacturing problem. Simple stuff, any engineer knows steel will rust, and rust alot in a salt environment, and is why this is also a manufacturing issue.
 

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Hey MM, I just did a search on this site here. And there is plenty of cases of this happening. How are they getting away with this? I sure hope you open that can of worms.
They should be forced to fix this on all the cars. Again do it right the first time and this won't happen. This is well known in the first gens and you mean its still an issue in a 2013?
Why? Its almost similar to inferior parts in the CVT transmissions.
So what would happen if someone did something that was meant to cause a persons car to crash, at some point in the future? What would that be called?
Since this is so well known for years, you would think by now this is considered something done on purpose.


There are more than this below.



 

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Could be some of it, though mostly its a loss of material thickness over time and then over stress of the material that is too thin for the load, and or pitting that then causes a stress riser, allowing for fatigue cracking to start and slowly progress into that failure. The ultimate problem is the lack of corrosion protection on the material allowing the part's material to corrode (rust), and flake away and reducing the gauge of the steel to a thinner and less strong structure. As well as the pitting described and associated stress riser.
 

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I do not want forced inspections. I do not want to spend the time or the money on something I am perfectly qualified to do my self. I do not want some punk monkey prying on, poking or hammering on or even touching my car.
 

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The car was purchased new and I would like to add that I am extremely grateful for all the comments on the original post . I am told that the failed parts will be available for inspection next week. I was amused by the PA standards discussing “rotted” parts. I did own a 1946 MG TC that had frame parts made of oak. Wood rots, iron rusts , maybe I’m grandfathered in😉
Is this next week yet?
 
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