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Discussion Starter #1
Hi - I am relatively new to Insight ownership, having bought a 2002 manual 14 months ago. I promised to fix any faults last summer, but somehow I didn’t get around to it. And so far have basically done nothing except cover 6000 miles to take the total to 149k.
Probably due to our awful weather (I am located in Northern Ireland), my rear axle (twist-beam, crossmember – call it what you may), is pretty badly rusted. I was thinking of removal for shot blasting and painting until I located the issue of lack of new bushes. But I guess it has to come out. I am actually worried that I could do more harm than good.
Any advice would be welcomed.
Robert
 

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Oh, I don't know. I don't think I'd take out an torque beam unless there was some known failure. There is a good product here in the U.S. which is used to stop rust on metal and provide a protective layer.

https://www.eastwood.com/por-15-sup...MIwsHg3_yF2wIVkVmGCh3T1gCeEAQYASABEgJ0hPD_BwE

I don't know that it is available in N. Ireland, but there may be equivalent European products. You could do some googling for the product.

There is a guy on here who found a substitute for the rear bushings. I can't remember the thread, but someone may come up with it.
 

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Discussion Starter #4
Thanks tryingbe and jime.
unfortunately the UK dealers tell me that the product is discontinued and cannot be supplied here. They did give me the part number, which allowed me to search online - but the only place I can find it is the US, and most won't do international orders/delivery.

I might go for the rust treatment approach.
 

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Rear Axle Rust

I just bought a quart can of Rustoleum gloss black paint and brushed it on the rear axle assembly. You need to scrap off the loose stuff. Then just paint on the Rustoleum. It contains oils to protect the metal from further rust. I just used cheap throw away brushes from the hardware store. Jacked up the rear end and placed it on jackstands and crawled under the car and went to town. I did 2 Insights and still had 1/3 of the quart left.

Larry
 

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Have you had a look on Rock autos website? Although its an American company it does deliveries to the UK and they might list the parts you need
 

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Hello BigUncle,
I am in a similar situation. The rear axle is in terrible condition as are many of the ferrous front suspension components. My Insight lived in Scotland for the first 9 years of its life and was presumably exposed to very salty roads for extended periods in winter.
The corrosion is far worse than any other car of a similar age that i have looked at and i have wondered if this has anything to do with the aluminium body and ferrous parts reacting with each other.
I am taking my car for it's MOT this Thursday and am a bit worried about the new stricter guidelines that are now in force. I will update this thread with the result of the MOT and any comments i get regarding the rust problems.
Thanks to Peterboat for the tip about Rock autos website.
 

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You are welcome for the help with the website, I use them all the time for my American cars great service and good parts in general. My car arrives next month from Japan, I suspect the first thing I will do is rustproof her to save the pain of finding rust where I dont want it :mad:
 

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Peterboat,
Good move to rustproof your JDM Insights ferrous parts when it arrives.A mate of mine bought a JDM CVT of similar age and mileage to my car.His car was virtually rust free in all the areas that mine was already quite heavily corroded.I don't know if the Japanese just don't use salt at all on their roads or if they use it much more sparingly but whatever they do it makes a huge difference to a cars condition.
If i have to replace any parts due to rust i will most likely have the new components powder coated.
Be sure to post the details of your Insight when it arrives and the best of luck with it.
Dave
 

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Hi Dave its a no salt at all thing, My Chevy Astro came from Japan and it was rust free as well, its an American Road Ultra made in American and then immediately exported to Japan, where they are much sought after. Other Astros I have seen do have corrosion and high mileage unlike Jap imports. Whist you might pay more you do get more in these case
Peter
 

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Discussion Starter #11
Thanks everyone for the responses.
For now, I cleaned up the axle as best I could on the car. I then applied "Aquasteel rust converter and primer" to it, before adding a coat of Hammerite.
I have to say that most of the rust was surface only, as when it was cleaned up, it was structurally sound.
I then took it to the MOT centre (In Northern Ireland we have centralised testing facilities which are fairly stringent), where it sailed through with a clean bill of health.

I may be interested in doing a better job at some stage in the future. I would hate to get to the stage where the car is still serviceable, except for this issue.
I will await the update on bluesunbeam’s car.
 

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Good news on the MOT.Passed with one advisory (bushes where the rear axle mounts to the body are slightly worn).
I did ask the tester about the state of the rear and front suspension components. From what the mechanic said the rear axle is in a similar state to yours BigUncle-lots of surface rust but still sound. The front struts are a bit worse. The area where they bolt on to the knuckle/bearing carrier show quite a lot of corrosion and the mechanic said they will probably be an MOT failure in 2 or 3 years time.
I am very pushed for spare time just now but i hope to remove the rear axle and get it bead blasted and powder coated in August and while it is off the bushes can be replaced. A big thank-you to tryingbe for all the time and effort he has put into finding a cost effective alternative to buying a new rear axle when the bushes are worn out-great thread.
Dave
 

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Glad to hear it passed ok mine will be in the country in two days time, looking forward to getting the car and enjoying the drive
 

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Discussion Starter #14
bluesunbeam - That is super news that the MOT was passed with relative ease, and that the axle is basically sound.
I must get a few photo's of mine - although the paint job is a bit rough (I do have 'before' photographs).
Looking at other threads here, the bushes might be a bigger issue than the rust though.

And Peterboat - also good news that yours is on its' way.
 
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