[FireFox31]

When trying to lift my 2002 E320 4matic wagon, I found that my front passenger's side lift point had rusted away. My other three supports appear to be solid with no rust. I used a wood block to distribute the weight over the surrounding solid body work. Is that a safe solution for now?

There's a suspicious tube deep inside that rusted hole. What is at the other end of this tube? Could it have dumped water inside this body panel, rusting away this support? Is there a nearby drain which should have let this hypothetical water out?

How can I replace this support so that it is structurally sound enough to act as a lift point again? Thanks!

 

[tabijan]

I'm not familiar with what's behind the skin or even the paint of these cars but it might be a sunroof drain. Pour an ounce or two down the forward corner of the sunroof opening and see if that's where it spills.

Sixto
98 E320s sedan and wagon

 

[FireFox31]

Brilliant. I will also check the A/C condenser and hood water collection points, since I don't know where those drain.

 

[tabijan]

Maybe the AC evaporator? That's over the transmission. The condenser is between the headlights

Peel back the trailing section of the plastic front wheel well liners. IIRC there's a mess of nuts in the wheel well and a couple of bolts from below ahead of the door. There'll be a quart or two of leaves and debris and hopefully no body rot ahead of the door hinge.

Sixto
98 E320s sedan and wagon

 

[FireFox31]

With the engine on and the fan on half speed, air comes gushing out of that rusted hole. Interesting how the internal body is somehow connected to the cabin air system.

I'll peel back the wheel well plastic and see what I can see.

Any idea on how I can have a body shop strengthen and rebuild this? Maybe weld a vertical where that piece is coming down. Then cut it flush, put the horizontal piece in, and put the lift point on.