A4 Structural rust

Phlipper1

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My A4 failed to get through MOT due to structural rust from suspension housing through to engine bay. Cost too high due to Engine removal/refit, plus suspension and weld repair. Seems like a design fault whereby mud and water collects on a ledge on the inside of the wing behing the strut and rots through to the engine bay.
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on the b5, b6 and the b7 the design is the same on that part but I've never ran into an A4 rusting in that spot... But than again the heat shield on those models mostly cover that edge so water and dirt are kept to a minimum on that particular edge. I can only say it probably was a bad weld from the factory or badly sealed repaired area (after an accident)

It's a PITA but if that is the only problem you might want to get one with a bad engine and drop yours into it, and all your upgrades unless just buying another one with a similar spec, isn't a problem...
 
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Yes, there does tend to be a "ledge" behind there that tends to fill up with "road junk" - really something that every B8 A4/A5 should be aware of and clean out every other year or so.
 
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on the b5, b6 and the b7 the design is the same on that part but I've never ran into an A4 rusting in that spot... But than again the heat shield on those models mostly cover that edge so water and dirt are kept to a minimum on that particular edge. I can only say it probably was a bad weld from the factory or badly sealed repaired area (after an accident)

It's a PITA but if that is the only problem you might want to get one with a bad engine and drop yours into it, and all your upgrades unless just buying another one with a similar spec, isn't a problem...
I've had the car for 10yrs and it had a K04 upgrade back in 2021 by APR - so it's got a Berg Wagner IC, Sports cat & Revo intercooler....although it's done 120k miles. I bought a Focus ST to use as a daily.....which made the A4 steering feel a little dull. See if there's any interest, although it is tempting to drop it in a newer A4.
 
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