I just bought my 2006 Volvo XC90 and other than it coming with only 1 key that is too big and looks like it was run over I haven't had any problems... Then I road in the back seat last weekend. When I opened the rear passenger side door I noticed rust spots on the bottom of the door frame as well as on the rubber seal which makes me think it is coming from inside that door. The car is only 2 years old! Is that possible? Has anyone else ever experienced this? I have a sick feeling in my stomach that this will turn into a large problem at the dealership.

I have added a photo:

 

I can only assume that the water drain holes on that door are clogged with FOD. I would clear the drain holes, sand off the existing rust with a power rotary sander, apply rust inhibitor or neutraliser (I know a British company makes a chemical that turns rust into non-rusting coating; I believe the company is called Holts) then finish with touch-up paint.

If you could supply a pic, that would help us help you better.


JPN