Shock Towers rusted-out!!!!!

annarborhawk · 03-09-2005, 08:21 AM

Sure my '99 Voyager has 100,000 miles on it. But I'm sorry a five year old vehicle simpy should not have it's shock towers go this soon. They are both rusted-out -- I don't know how thing hasn't collapsed yet.

Dealer says it's normal, and common problem, and that they will "cap" the towers for $800.

Anyone know of a secret warranty, or whether the "caps" will even make the thing safe to drive? IMO this should be Chysler's problem, not mine.

jawss · 03-10-2005, 02:36 PM

I have the same problem with my '98 Caravan, just on the drivers side...so far. Im a welder so Im going to fix it myself. The wiper cowl comes right off, exposing the whole strut cap. If Im not mistaken, this cap is spot welded on to the body therefore can be removed by drilling out the spot welds. Im going to scour the local junk yard till I find a good cap and weld it in. I dont have to go to this extreme but I want to do it right the first time. I could just remove the strut and seam weld a patch of metal over the rusted part. But like I said, Im picky. And your right, this is a common enough problem with these vans, Chrysler should be doing a recall on these. Good luck with yours!

jawss · 03-11-2005, 09:27 AM

Quote:

Originally Posted by evictor

Where you located. Could I buy you a case of beer and a steak dinner to weld a plate for me. :-)

heheheheh Im in NB Canada and you'd have to make it a 24 of beer.

t4ia · 03-14-2005, 02:10 PM

I have someone who has a similar problem on their Caravan. It is I think a 98 Caravan. Does anyone know of any good shop who can do a reliable work in Toronto/GTA area in Canada. BTW, those who got the strut tower rust fixed, is it good and reliable. I mean after getting that fixed can you rely on the car? Are those areas fixed strong enough and any chance of them breaking?

HiRez_L · 03-14-2005, 02:58 PM

I guess they don't build them like they used to, as both my 89's and my 88 are still solid in the strut towers . . .

dougpeng · 08-22-2006, 07:22 AM

I have a 1999 Grand Voyager with 190,000km (120,000 miles) that has exactly the same problem. I live in Toronto where the roads are heavily salted in the winter time, but have not witness this kind of rusting on any other car I have driven. The two front strut towers are rusted out at the top so badly that I'm surprised the entire assembly has not collapsed. It looks like an accident waiting to happen. I can just see them collapsing after hitting a big pothole on a freeway. I called Chrysler, and found that they sell a kit called the "Strut Tower Corrosion Repair Kit" that consist of a metal cap plate, screws/bolts and adhesive. The left and right cap plates are slightly different in design due to the opposite symmetry, so please specify if you are only replacing one. I read a few more websites that said the left tends to rust out faster than the right. THis is also the same in my case, but my right is really bad too. These pieces despite belonging to the kit, are priced individually. The metal caps are $33 CAD each, and the screws is another $36. Personally, I think you can pick up those same screws for like $3 at Canadian Tire, but then you don't know which ones you need. Basically, it's $100 for everything. As for adhesive, it's another $76 CAD but the dealer did not have it in stock so I did not buy it. Good thing. I brought these pieces to an independent body shop who told me they can weld the two caps on instead of bolting them on (hence wasted $36 worth of screws/bolts but thank God I didn't pay for the adhesive) for about $250 CAD. Now that's a steal of a price since I know the man, so expect the market cost to be much more. Just looking at it, I think the windsheild wiper assembly or cowling needs to be removed to make room for installing these caps. My mechanic used a chisel and with relatively light tap, the rusted tower cap flaked right off exposing the strut assembly below. This cannot possibly be safe despite Chrysler calling it a cosmetic problem in their 2002 TSB (see below).

dougpeng · 08-22-2006, 11:04 AM

Got some more information on this problem. Turns out Chrysler knows of this problem and has issued a TSB in 2002 addressing it. See below:

Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion

OVERVIEW:
This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s.

MODELS:
1996 - 2000 NS Town&Country/Voyager/Caravan

SYMPTOM/CONDITION:
Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender).

DIAGNOSIS:
Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures.

NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS.

dougpeng · 08-22-2006, 11:17 AM

Saw your Caravan/Voyager Posting on automotiveforum.com regarding rusted out strut towers. I also live in the GTA and found a cheap place to get them fixed. You can e-mail me at dougpeng@rogers.com or check out this posting on automotiveforum.com for more details.

Vats · 08-23-2006, 07:41 PM

Same problem on my 1999. Not completely shot but this should not happen. Chrysler say the strut towers are cosmetic, but the last thime I Checked a strut tower is structural.

Seems every Van around the 1998-2000 era has the same problem.

Mbriggs · 08-25-2006, 09:36 AM

I just spent $390 to get the strut towers welded on my '98 with 145k.

Sounds like the kits would have been cheaper!

mnwalleye · 08-29-2006, 09:05 PM

My shock towers are just fine on my 98 but I have some rust wearing through on the drivers side rocker panel. I've taken it to a body shop but they want thousands to fix this. I've found this site ://www.rustrepair.com/Rocker_panel.htm that sells rocker panels for vans but wonder if anyone has any experience with this. I'm willing to put money and some labor into as this van still looks and runs almost new with the excemption of this rocker panel. A good looking van is a well cared for van I always say.

thanks,

MNWalleye

ATOZBODY · 09-22-2006, 01:20 PM

I own a shop i have llooked at dozens of these with the same problem! This is a safety item and should be taken serious. I have a collection of pictures of this too. has anyone done the recomended repair and how is it done? How much time to do it?

Soccer dad · 09-22-2006, 01:54 PM

When I bought my 96 about five years ago I took it to the dealer in town to have it certified and they fixed the rusty towers for free something about a recall or service bulletin was the reason? You may want to look into it?

Stevo2 · 09-26-2006, 06:21 AM

Here's the complete Service Bulletin.

kekoa747 · 11-16-2006, 10:01 AM

Depending on the extent of the corrision there are two repairs on is a cap that fits over the top of the tower the other is a tower replacement.
I just did the cap repair it is glued and rivited. First you cut out the rusted area. the repair kit from chrysler has a template for the cut area. Then you place the cap, drill and screw it into place. then drill the rivit holes. remove the cap sand or grind off the paint from both the twoer and the inside cap.
you can by the adhesive from chrysler or use 3m structural adhesive from you local body shop 45$. 3m get 340$ for the applicator gun. I used and SEB or i think any other gun would work. seb gun was 55$. apply adhesive to both cap and tower. screw and riviet to place.
As this repair only seems to take side loads and not vertical loads if you where concerened about the saftey of the repair o strut brace would strengthen it more.

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