'04s are covered under the 12yr/unlimited mileage corrosion warranty. I got a little sticker in the mail from MINI USA a while ago to put in my owner's manual to reflect this change.

'02-03 MINIs have a 6yr/unlimited mileage corrosion warranty...

 

Well THAT is excellent news!

 

Yup. Apparently, the 04s were initially a 6yr warranty as well.

I'm not sure what changed with the 05-newer (different anti-corrosion treatment?), but they changed over to the 12yr warranty. I'm thinking that this change was actually made for the '04 model year, hence the reason why MINI updated the warranty on the 04s too.

 

I just dropped my '03 r53 off at the dealer and they are fixing the rust under warranty!

 

Awesome!

 

I just got the cooper back lastnight and the repair looks great, however, there was water trapped in there from when they washed the car for me. So now that I have the area repaired, what is everyone doing to KEEP the water out? Did anyone ever figure out where the hell it comes from?

 

Checked mine, and one side is really showing rust where the plastic was over the non-painted area. I have an 02 MC, and the dealers are 2.5 hours away from me. I bought a POR 15 kit in clear and am gonna try it. If it rusts under the clear I will be able to see it and hit it again.

 

I'm looking at possibly getting a '03 S. I want to inspect the area prior to taking the plunge. Can someone please point out exact area and method to uncover this spot for my pre-purchase inspection? Some detailed photos would be great. Also, when removing the door sill rubber strip, is this basically a pull until it pops off the lip? I don't want to rip this strip off in front of the current owner and damage it.
Appreciate the help.
-SB

 

Just pull the rubber strip up and look all along the bottom of both doors. Also, take your hand and feel along the outside of the door at the very bottom. Mine rusted under the rubber strip and all along the bottom of the drivers side door. I got tired of getting the run around from the dealer that I traded my 03 cooper S in. Miss the car, but I dont miss dealing with the MINI dealer. Good luck in your search.

 

Will do. Thank you SSM

 

EVERYTIME I washed the MINI or the car got rained on, I had to pull the rubber strip up and dry it. Its a pain, but if you dont do it, It WILL rust again.

 

I have an '02 and find myself doing the same thing. It really is a pain.

 

After wiping the wet area on the sill, I leave the weatherstripping off the sill overnight in the garage after it's been washed. The tracks in the weatherstripping are dry by the next morning.
Shellback, I have a couple of pictures of the affected areas before repair was done in my gallery.

 

Thank you for the photos. One more item to add to my pre-purchase checklist.

 

I do this, too. I also use compressed air to get water out of the track.

 

Hi,

In the Netherlands we have the same problems with the door sill and the rust.

At this moment I am in discussion with my dealer and Mini Netherlands... They first did not wanted to recognise the problem and told me that they never heared of this problem...until I told them that many members of the Dutch new mini club have this problem and issued it before me to their dealers and Mini Netherlands... Now they called me back and told me that they will repair the rust under warenty and place new designed seals on both of the doors, with a new and better draining system!!! Anyone else heard of these new designed seals???

Sorry if my English is not perfect....

 

I've never heard of a revised seal, but if one exists - I'm most definitely interested in it!

I'm tired of water building up in my door sill. I live on an island, so it's just a matter of time before the salt air starts getting to the door sill...

 

We will see how it goes...

 

I coated mine with POR, and it fixed the obvious. There is one spot at the top of the pinchweld where it still shows active rust however. Is it possible that there is rust down inside the seam? Has anyone remove the black plastic sillplate and done an inspection from under the car?

 

To my understanding it is no problem with rust down inside the seam, as the water will not stay in the seam due to a draining system.

 

wish i had seen this thread 2 years ago. just found 8 rist spots under my sills on my 03. soem of these "spots" mind you were 2 inches long and had taken out ~5mm deep of metal. just sanded the rust areas down and painted over the area with some black rustoleum. will check it in a few months to see how its doing...

 

Not sure if this has been mentioned but does anyone know what the Canadian rust warranty is for an 06?

just bought it and we just had some heavy rain, i notice water remains on the door sill. then i notice a tiny spot of rust near the front of the sill...

i'm in Toronto Canada and would love to know for sure how to proceed.

Cheers,

 

I have recently used Rust Bullet to great effect on the driver's side door seal area. Removed the interior sill, minor sanding with 100 grit to whole length, clean with isopropyl alcohol, two coats of standard Rust Bullet, then a top coat of Rust Bullet Black Shell. After some rain, the water was beading up along the treated area. I will have to get some photos when I do the passenger side later on.

 

I wish I had known about this sticky a few years back also. I checked today and I have two spots of rust on both door sills. I will be treating them this week with a rust inhibitor and then I will be installing a CounterAct electronic rust inhibitor system on my 03 DS/W BUG ETER.

Here is a link describing the CounterAct system.

http://www.counteractrust.com/

 

I got info back from the CounterAct company on their rust inhibiting system. The model for my car will be priced at $349.95. Since I plan to keep my MINI until they pry my cold, dead fingers from the shifter and steering wheel I think this is a wise investment