[peterjim13]

Had seen similar but not so bad points with rust on my 2012 XUV5OO as well. Even though these marks were almost an year old, I took them to an FNG and repainted the portions by rubbing off the rust.

It wasnt this bad anyhow.

But I am a bit concerned about whether there would be rust around areas which are masked by door pads, wiring etc.

[Mach_1590]

I don't know if it is with all the Mahindra's but our XUV 5OO's door started rusting in under 3 years. The service center took care of it after a lot of haggling. The culprit perhaps is hard coastal water which might be seeping in through the rubber beading during the routine pressure wash. Although Endeavour and i20 also spent 2 years in the same environment but there isn't a single squeak from the door.

[piiyush21]

Even I'm facing this issue with my 2015 W6 model. Even though I have a dedicated parking spot and Delhi anyways does not get that kind of water either from rains or shores, yet still, the XUV doors have started rusting from the corners.

[giri1.8]

Apart from the known drawbacks of rusting, car's structure might lose its integrity, thus making NCAP rating invalid. Experts can correct me if it's proven wrong!

[Indian2003]

When the Ford Figo was renamed the Ford Ka for Europe, They made quite a few changes. The car was produced in India.

The selling points were better steel quality, new and better engine mounts, better sound proofing, new and better seats and fine tuning of the steering and chassis. From what I remember from 2016, they mentioned plastics with "European quality", whatever that means.

Does that mean that Indians are being offered cars with sub standard steel quality and therefore the rust problems?

The first thing I did to my car when I bought it used in 2012 was rustproofing with lanolin. All doors and hollow rooms were drilled and sprayed with Fluid Film. Nowhere on my car will you find such serious rust and my car lives a very hard life in the winter season.

Some spots do appear around the stone chipping but I puncture them and apply oil until I get it fixed. This to prevent further rusting.

[Stolidus500]

This is ours from 2012, currently fixed. But only car in our garage to ever rust

[farhadtarapore]

Update:
Mahindra has replaced both the front doors on my XUV500. They bore half the cost! The work done by the workshop is awesome! Happy to see such customer obsession by an Indian auto company.

[shancz]

Originally Posted by farhadtarapore

Update:
Mahindra has replaced both the front doors on my XUV500. They bore half the cost! The work done by the workshop is awesome! Happy to see such customer obsession by an Indian auto company.

That's a happy surprise in an otherwise gloomy state of affairs for the ICB (The Indian Car Buyer | Struggling with problems in brand new cars).
Kudos Mahindra
Hope that the cause of this rusting has been rectified in t he manufacturing process as well
Hope others can take a leaf from Mahindra in customer service.

[AutoNoob]

Originally Posted by Stolidus500

This is ours from 2012, currently fixed. But only car in our garage to ever rust

Any rusting on A-class surface is bad, but the through rusting on the structural portion (sill members) is really concerning . To repair it, whole section needs to be cut and fresh piece welded in place. Which itself is very concerning.

Integrity of whole body shell is compromised.

What's your plan to resolve this rusting?

[RT13]

This is good customer service considering most automotive orgs would stall you given the age of the car putting it just outside of warranty.

But its really lousy manufacturing quality. And given the number of other people popping up on this thread, it isn't a one-off and isn't restricted to regions which experience heavy rainfall and humidity. Pretty concerning actually.

Good for them on the former. Hope they've improved the latter.

[neil.jericho]

A friend in Cochin who owned a Jan 2017 registered XUV500, also found massive rust at the bottom of the front door. It was much worse than the pictures on this thread. This was a daily use car and the amount that the door had rusted was shocking! Even the rear tailgate had some early signs of rust. Since he was selling the car, he lost quite a bit of resale on these two fronts.

The only car that I know of with rusting issues is the old Fiat Punto, where minor bubbling and rust appears once the car nears 10 years of age.

Anyway, kudos to Mahindra for replacing the doors while bearing 50% of the cost.

[Stolidus500]

Originally Posted by AutoNoob

Any rusting on A-class surface is bad, but the through rusting on the structural portion (sill members) is really concerning . To repair it, whole section needs to be cut and fresh piece welded in place. Which itself is very concerning.

Integrity of whole body shell is compromised.

What's your plan to resolve this rusting?

This rusting has been repaired by welding in a new piece just as you suggested. I plan to sell this contraption at whatever price I can get and buy a crysta. Never seen rusting like this in any other car we own. All hail Mahindra.