We have had a bit of rain in the last few weeks and the missus complained about wet carpet in the front of the car. Traced it back to the front wind screen and took the windscreen trims off thinking it wasnt sealed well. Started digging out the old sealer and the screwdriver went straight through. Found my leak i have about 5 or 6 rust holes on top of the wind sreen. Also found rust at the passenger side door frame. Has anyone else had rust issues?

yep. big problem. Screen has to come out, rust cut out, new metal welded in, repaint, reinstall windscreen. Not a simple DIY job. Used to be a big problem with earlier Mitsus - the signas used to do it badly. Mitsu got it right in the second gen and younger models though - they don't seem to have the problem, but who knows, in the future, when they get older?

We had continuous rust issues with the roof in the 1990 Lancer 5 door hatch we had once upon a time. Dad cut it all out but because he never used clearcoat on it (it was a dark blue) the roof ended up looking like a dalmation.

yep. big problem. Screen has to come out, rust cut out, new metal welded in, repaint, reinstall windscreen. Not a simple DIY job. Used to be a big problem with earlier Mitsus - the signas used to do it badly. Mitsu got it right in the second gen and younger models though - they don't seem to have the problem, but who knows, in the future, when they get older?


Very true what you say about the sigmas, I had the exact problem with massive rust all around the window.

I ended getting my window taken out then did most the rust repairs myself to save money. Cut out what needed to be gone and rust proofed what was left.

Fixed the missing sections using fibreglass then bought some sika-flex and put my window back in.

I think total cost was around the $100 mark.

Well i scraped the rust away put on heaps of rust converter then a few days later filled with silicon and then put the trims back. Not the best thing to do but no more leaks.