WARNING....SPLASH SHIELD CAUSES RUST TO SUB-FRAME!
 

What a disaster.....!

A couple of weeks ago, I accidentally dropped a hose clip down into the engine bay. Looking from the top of the engine bay, I couldn't find it anywhere! So, I decided to look underneath and figured it may be sitting on the topside of the engine splash-shield/guard.

So, after removing the 14 bolts/screws from the shield, and dropping it down, I finally found the clip. But what else I found was shocking!

The whole of the front of the sub-frame and the splash tray mounting-bar had been heavily rusted. In fact, the front mounting bracket for the LHS torsion strut (lower control arm) had completely rusted away! (see photos 1 and 2 attached).

How did this happen? Well.........it turns out that the plastic splash-shield has moulded wells in it, which are mounted flush around the front of the sub-frame (large bar and control arm mounting bracket); and the splash-shield mounting bar. Also, the bumper acts as a funnel for rain water, to flow onto the topside of the splash-shield.

BOTH OF THESE PLASTIC WELLS HOLD POOLS OF WATER, AND HAVE NO DRAIN HOLES! ANOTHER BMW DESIGN FAULT? If you live near a beachside suburb like I do, or drive on salt-laden roads in the winter, these wells could be full of salty water!

Anyway, to fix it, I had to buy a rust-free sub-frame from a wrecking yard and have the rusted section cut out and replaced by an expert welder.

The whole procedure took about 2 weeks to organise and about $700 to repair. I spent about 4 hours removing and replacing the splash-shield, splash-shield support bar, brake/transmission cooling duct and bumper. All caused by having no drain-holes in the splash shield....NOT HAPPY!

Needless to say............ my splash shield now has 4 new drain-holes to clear the pooling water away from the frame components (see picture 3.)

This is a warning for other e53 owners. If your X5 is around 10 years old, you should remove your splash-shield, check for rust on the metal frame and create some drainage points.

Let me know if you have experienced a similar problem.

holy shit. i can't believe the rust. you must feel a difference in steering/suspension with the replaced sub-frame I assume?
I live in an extremely dry climate (sadly) so this is not an issue for me, but I may as well check it... no harm, just time.

Didn't notice anything of this nature on mine... came from Utah and then California but not sure how much salt it saw. Here in TX it won't be an issue... but I will be putting in drain holes anyway.

Thanks for the PSA.

Holy shit. I have not seen that on mine at all. Nothing even close. And I live in NE. I do keep mine in the garage and wash after every salt drive. But wow.

From what I've seen on my E53 (10 yrs in "rains almost every summer afternoon" FL), there's something more then just water at work here.

Those areas on my X still have the factory black coating.

That shield drains water, the front is higher then the rear when installed.

It looks like someone parked the X in salt water for a few months!

Mine is like brand new due to the leaking power steering return hose :(

My oil pan seepage has created an effective moisture barrier to several underbody components :thumbup:

2002 X5 3.0 298,000 miles
2014 428i 16,900 miles (I get to drive the CEO's ride this week!)

2004 325i sold at 123,600 miles
2001 325i sold at 66,000 miles

:iagree:

:iagree::iagree:

Mine looks mostly factory new.

But I am extremely curious, why cut and weld on the sub frame? Just replace the whole item!