My understanding is that they will cover this if its still under the 3yr/36k warranty, but not the 150k corrosion warranty because its not rusted through.

 

Rust Through coverage is 6 years, 100,000 miles.

 

I was told differently regarding the rust through warranty. You would know for sure though.

I was also told that my emissions warranty was 10yr/150K on my 2006 Cobalt SS/SC. I'm so confused.

Anyway. I had some paint rubbing off where the doors meet the rubber and rust bubbling under the hood-they fixed it no questions asked.

 

Looking back, it appears that you are missing the seam sealant that would keep water and oxygen from reaching that area. Here is mine.


See the painted sealant over the seam?


Either they changed the manufacturing process, or your door was reskinned and in such an event, GM is not the culprit.

 

"Either they changed the manufacturing process"

This!

There were problems with some of the earlier cars.... some got proper sealant in the pinch weld and others didn't. Mine is faring rather well (2007) but others newer and older are not. It was hit or miss. Nice to see they improved the system (right before killing off the car)

 

Thanks for clearing that up. The OP should just grind it down a small bit to remove the cancer and seal it himself.
Just trying to help.

 

Say, what is that black plug in my photo for? Is it for the rust proofing?

 

That black looks repainted. Its not very smooth like mine is. Almost looks like overspray on the plug. The shop or whoever did the repair did a shoddy job.

 

Yes, he said the previous owner had it done.... More than likely on the cheap.

 

Well unfortunately there is no fix really. Rust WILL come back, it's cancerous. The only way to properly fix it is to remove the rusted panel and weld new sheet metal in... Not sure that you could do that on the door.

So I'm wondering if I should caulk my door so it has somewhat of a seal? Mine has rust bubbles but they're lower than the seam is...