[colt808]

I'm sure most everyone who takes good care of their rides make it a point to check for rust during regular washings. Being that I'm on an island which has such a harsh environment (salt air, acidic soil, and a regular rainy season), I'm pretty anal about rust. I check the body, door jambs, hood, bumper, around the gas cap and the undercarriage regularly. A minor paint chip and I'm busting out the sandpaper, glazing putty, and paints. I thought I was winning the fight, but today I found a 2" long rust hole just behind one of the hinges of my tailgate! Oddest place for rust...I have no idea how the paint could've been damaged there as it's covered by the hatch. And it's not really visible from the top or sides and pretty much hidden behind the hinge.



There is an actual hole there, but when I pulled down a part of the headliner, I can't see it. Must be a double walled section of metal. The gap is too small for me to get in there and properly take care of it, so I'm stuck with having to remove the hatch. I even tried gun cleaning brushes and a Dremel with flex attachment.

So, has anyone else found rust in this area? If so, any trick/tool, suggestions to take care of it right without pulling the hatch? If I have to remove the hatch, how heavy is it? I know it's a 2 (maybe 3) man job for sure, but I'd like to have an idea before busting a nut on this. If anyone has done it, was there any problems re-aligning?

[ratmonkey]

Pretty common area for any vehicle to rust out. Water gets trapped there.

You will have to remove the hatch. If its a 2" hole I'd want to patch it with metal instead of filler.

[318jeepcherokee]

my 96 rusted there too.