The axle rust is normal and you won't be able to avoid it. Some mufflers stay shiny while other tend to turn with heat. It looks like rust, but it's more of a discoloration. I painted mine with black barbeque grill paint. It's held up well and is easy to do.
After every 1 or 2 wheelin' trips I wash the underneath down real well and climb under there with a rattle can. I spray all the dents, gouges and scratches, along with the rusting areas. Doesn't take long, and as I live by the coast it helps keep the rust at bay.
Flat paints are the easiest to apply, but they go on real thin and I've found they rust through pretty quick. So I now use Rustoleum Professional Semi Gloss on everything. Their Cold Galvanizing Compound spray is a good base for real rusted areas.
I guess I can't find a spot underneath without rust. It's unfortunate in New england but if I had to weld anything I might as well add 4 hrs labor to chisel off the rust. Thank You chrysler for not coating the underside with some kind of undercarrage paint.
Picture the underside of your JK half brown and half black.
yes I have rust in areas as well...the ones that bother me most are on the inside; under the steering column just inside the dash and under both sides of the rear seat on the rear post. haven't had time to bring it to the dealer just yet, but talked to them and they said "just bring it in and we will replace it". so we'll see!
When I did my 1" BL, I found that the two rear body mount bolts where rusting, when I removed them, a waterfall of rust and mud came spewing out. So check those on yours if you've done any water fording.
Oh yeah and sooner or later your door hinges are going to show signs of rust.
I was looking at a Deep Water Blue JK on the dealer lot this weekend and it had rust around the windshield bolts...how about that! Makes me think twice about replacing my JK under the Lemon Law...I may do a buy back and find something else to spend my money on with a little better quality.
Just picked up my JK Saturday. Sunday looked under it to check axle breathers and WTF????? Both front brake assemblies and both drive shafts look like they pulled 'em out of the Ohio river and slapped them on the Jeep.
Calling dealer today to biatach!!:bawling:
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