I have just had my front bushes replaced, requiring the front subframe removal. However it has been discovered where the sub frame meets the chassis, this area was so rusty the ‘lug’ which fits into the subframe had broken away as a result of the rust. Cutting out the affected area showed that the rest of the chassis was perfect, both through to the front of the car and towards the rear. Due to the location of the telescopic suspension leg, the affected area of the rust cannot be seen. It’s only when removing the suspension leg that access to this area can be seen. See pictures attached. Has anyone else experienced this issue? Anyone have any idea where the water is getting in to cause this issue?

 

It always astonishes me just how rusty these vehicles get in the UK. Sure hoping you can repair this damage at a reasonable cost.....

 

Pretty standard, but an easy bit of welding once the subframe's off. I wax injected the cavity after doing this repair with this: https://www.rust.co.uk/product/cat/u...rust-proofing/

 

Bladerunner919 - do you know how the water is getting into this area and why the rest of the chassis is not affected?

 

IDK for certain, but my guess would be that the gap behind the crossbeam 'tower' for the upper control arm is a pretty good trap for cr*p to accumulate and help the rotting process. There's not much effort put into seam sealing either.

Pretty common place to find it, as blade runner notes.