MajorCommonBody & Rust

Hyundai ix35: JM Tucson Wheel Arch, Sill and Tailgate Rust

JM Tucson Wheel Arch, Sill and Tailgate Rust is a common body & rust fault on the Hyundai ix35 on the 2004–2009 cars, and we rate it major. Putting it right costs $600 to $5,000 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 41 documented faults on the Hyundai ix35.

Vehicle: Hyundai ix35
Years: 2004–2009
System: Body & Rust

This page covers the Hyundai ix35 as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Hyundai ix35 faults41 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Body corrosion yet. We would rather show none than show a picture of a different part.

What goes wrong

First-generation JM Tucson models (2004–2009) develop structural and cosmetic corrosion in the rear wheel arch flares, lower door sills, tailgate lower edge, and chassis rails when approaching 15+ years of age in New Zealand and Australian conditions. Factory corrosion protection on these early models was insufficient for coastal and wet climates. Rust in the sill sections can progress to structural compromise, resulting in Warrant of Fitness or Roadworthy Certificate rejection. Budget for rust remediation is essential on any unrestored JM example above 150,000 km.

What you would notice

Paint bubbling and lifting on rear wheel arch flares
Visible surface rust along lower door sill edges
Rust staining or dampness inside boot floor or under mats
Soft or perforated metal when pressed on sills or tailgate lower edge

How to check it

Where to look. Rear wheel arches, door sills, lower tailgate edge, chassis rails

Inspect all four wheel arch inner lips and outer flares closely with a torch — bubble rust is often hidden under the plastic arch liner.
Run a finger firmly along all four door sills feeling for softness or perforation.
Lift all floor mats and the boot mat to check for rust bubbling from beneath.
Inspect the lower tailgate edge.
Get underneath the vehicle and examine the chassis rails and subframe mounting points for corrosion.

Parts involved: Body corrosion.

What it costs to put right

$600 to $5,000 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has any rust repair or rust-prevention underseal been carried out?”
“Has the vehicle spent time near the coast or on unsealed roads?”

Now check the Hyundai ix35 you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Hyundai ix35 buyer questions

Is jm tucson wheel arch, sill and tailgate rust serious on a Hyundai ix35?

We rate it major and common on the Hyundai ix35. First-generation JM Tucson models (2004–2009) develop structural and cosmetic corrosion in the rear wheel arch flares, lower door sills, tailgate lower edge, and chassis rails when approaching 15+ years of age in New Zealand and Australian conditions. Factory corrosion protection on these early models was insufficient for coastal and wet climates. Rust in the sill sections can progress to structural compromise, resulting in Warrant of Fitness or Roadworthy Certificate rejection. Budget for rust remediation is essential on any unrestored JM example above 150,000 km.

How much does it cost to fix on a Hyundai ix35?

$600 to $5,000 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Hyundai ix35 years are affected?

Our research records this fault on the 2004–2009 Hyundai ix35. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Inspect all four wheel arch inner lips and outer flares closely with a torch — bubble rust is often hidden under the plastic arch liner. Run a finger firmly along all four door sills feeling for softness or perforation. Lift all floor mats and the boot mat to check for rust bubbling from beneath. Inspect the lower tailgate edge. Get underneath the vehicle and examine the chassis rails and subframe mounting points for corrosion. Look here: Rear wheel arches, door sills, lower tailgate edge, chassis rails