2003 MITSUBISHI LANCER EVOLUTION Structurebody Problems

Corrosion on cross member

UPON INSPECTION OF THE UNDERCARRIAGE IN THE REAR, AREAS OF SEVERE CORROSION HAS DEVELOPED UNDERNEATH THE REAR ON THE ALUMINUM SUBFRAME BAR THAT HOLDS THE REAR DIFFERENTIAL AND OTHER SUSPENSION COMPONENTS IN PLACE SUCH AS THE REAR DIFFERENTIAL & LATERAL CONTROL BARS THAT CAN SURELY COMPROMISE THE CARS ABILITY TO DRIVE IF UNNOTICED. ADDITIONALLY THE FUEL LINES ALONG THE GAS TANK, AS WELL SURROUNDING SURFACES ON THE DRIVER SIDE REAR, HAVE DEVELOPED NOTICEABLE CORROSION AS WELL THAT IS ALSO PROVING TO BE A LARGE AREA OF CONCERN. I AM CERTAINLY CONCERNED FOR MY SAFETY WHEN OPERATING THIS AND THE VEHICLES ROAD WORTHINESS BECAUSE OF THESE AREAS. THIS VEHICLE IS BY NO MEANS HEAVILY MODIFIED AT ALL, THE VEHICLE IS NEVER OPERATED BEYOND ITS LIMITATIONS/AGGRESSIVELY AS IT'S ALWAYS BEEN GREAT FOR ME AS IS, AND IT RESEMBLES EXACTLY THE WAY IT DID WHEN IT LEFT THE FACTORY. SOURCING ORIGINAL AND DOT...

SEVERE REAR FRAME RAIL UNIBODY RUST. SPECIFICALLY WHERE THE REAR ALUMINUM SUBFRAME MOUNTS TO THE BODY. MY VEHICLE, ALONG WITH THOUSANDS OTHER, HAVE SHARED SIMILAR RUST AND ROT FROM THE EXACT SAME LOCATIONS ON 2003-2006 MITSUBISHI LANCER EVOLUTIONS. ABSOLUTELY NO FRAME PROTECTION FOR THE STEEL BODY. THERE IS ALREADY A RECALL ON THE FRONT SUBFRAME FOR RUST THAT CAN ALLOW THE FRONT LOWER CONTROL ARM TO FALL OUT. THE SAME COULD HAPPEN TO THE REAR OF THESE VEHICLES WHERE THE ENTIRE REAR END/DRIVETRAIN AND SUSPENSION COULD FAIL AND FALL OUT, POTENTIALLY CAUSING A SEVERE SAFETY ISSUE. ANY PART OF THE US WHERE HIGH HUMIDITY/RAINFALL OR WHERE ROAD SALTS/SOLUTIONS ARE USED ACCELERATE THE CORROSION PROCESS. BEING A UNIBODY VEHICLE THIS IS A SERIOUS PROBLEM AND DESIGN FLAW. IT HAPPENS OVER TIME AND DOESN'T DISCRIMINATE TO CONDITIONS. HAPPENS ON BOTH DRIVER AND PASSENGER SIDES OF THE REAR FRAME LEGS WHERE THE SUBFRAME...

WHILE REPLACING FRONT SUB FRAME STRUCTURE UNDER RECALL FOR RUST AND CORROSION, RUST DAMAGE TO THE REAR STRUCTURE WAS NOTED BY DEALER. UPON FURTHER INSPECTION, THERE ARE HOLES IN THE REAR STRUCTURE AS WELL.

PAINT ON MY 03 EVO BEGAN FLAKING OFF, ROCK CHIPS BY BOTH BACK PASSENGER DOORS, 24K MILES AND I HAVE TOO MANY ROCK CHIPS EVERYWHERE, MY 98 CAVALIER DOESN'T HAVE THIS MANY ROCK CHIPS. *JB

ROCK CHIPS BEHIND THE DRIVERS SIDE REAR DOOR. MANY LITTLE CHIPS RUNNING UP THE DOOR FRAME. THE CHIPS ARE IN THE CREASE OF THE DOOR JAMB. I CAN PROVIDE PICTURES. I TOOK THE CAR (2003 MITSUBISHI LANCER EVOLUTION) TO HALL MITSUBISHI IN NEWPORT NEWS VIRGINIA AROUND JANUARY OR FEBRUARY. THE SERVICE MANAGER SAID IT WAS ROCKS KICKED UP FROM THE ROAD AND DIRECTED ME TO CALL A TOUCH UP PAINT REPAIR SPECIALIST. I HAVE TALKED TO MANY OTHER LANCER EVOLUTION OWNERS AND SEEN FIRST HAND THAT ALMOST EVERY EVOLUTION HAS THIS PROBLEM. I CAN PROVIDE PICTURES OF THE AREA IN QUESTION. THE CHIPS ARE TINY, BUT THEY ARE IN A PLACE ON THE CAR THAT WILL BE VERY SUSCEPTABLE TO RUST. I STARTED NOTICING THE PROBLEMS ABOUT A MONTH AFTER I BOUGHT THE CAR. I BELIEVE THE PROBLEM IS CAUSED BY A IMPROPERLY ALIGNED REAR DOOR. SO FAR I HAVE...