TikiX

We had a 95 Cherokee 2 door that I thought was the most perfect vehicle ever, except the roof was seriously rusted thru above the A, B, and C pillars. I’m talking holes almost as big as my hand. I tried a quick and dirty patch job, and it worked for a while, but the rust was too extensive and we sold it after a couple years.
Now looking at getting another, but I want to know how common that is. Certain years? All years? Some models? All models?
I figure water can only get in thru the roof rack holes, are there models that didn’t come with roof racks?
Many Cherokees I see around here are the same, or getting there. Always the spots right above the pillars. Grand Cherokees don’t seem to have the same problem at all, but I don’t like them as much.
Full disclaimer, I live on a small island in the middle of the ocean, so you’re never more than a few miles from the ocean. Plus, it a very warm and humid climate with lots of rain. Everything rusts here, to some degree, but not like Cherokees.
I searched here and read many threads on roof rust, but didn’t see any talk about the cause or how common it is.
So, is it common in other rust belt areas? Or just here?
I really want to get another Cherokee. Looking at 95-01.
Help?

jordan96xj

I live in a terrible rust belt. I don't see pillar-top rust problems all that often. Floors, wheel wells and fenders, rocker panels, and suspension brackets (control arms, etc). Are the main/first victims. But most of our salt/moisture is coming from below.

PatHenry

I agree with Jordan - as I also live in the same "snow belt" portion of the continental U.S., I see the same typical rust.

There are definitely XJ's that did NOT come with stock roof racks, look for an SE/base model - my 95 for example does not have factory roof racks.

Unfortunately it may be difficult to find a wide selection of local XJ's available in HI. If you're willing to pay a little more to get one shipped in from the mainland, you might consider trying to get one that has lived in Southern CA/"Southwest" since the rust tends to be much less severe.

On a side note, I have a friend who moved to your beautiful state several years ago and loves it there - she's currently in law school and doing great.

Jeepwalker

Probably due to a combination of aerosolized salt in the air landing on the top surfaces of the vehicle where the paint is old and weather-worn ...and rusting from the top down. It's not a problem in the rust belt, but not uncommon in other waterfront locations like FL where rust can occur around the horizontal areas of the front and rear windows. One thing that could help a new owner of an old XJ, would be to ensure the top roof-rail caulking was in good shape, and paint is kept up (for protection). Drain channel caulk often cracks on older vehicles making a great place to accumulate and begin rusting. Keep the top drain channels clean of debris. Finally, might not hurt to consider removing the roof rail chrome strip to keep salt from building up underneath where it's hard to wash off.

The good news is a big rust hole makes it easy to pass a cocunut drink right to the driver!!

PatHenry

Then you can call my friend when you get busted for the OUI and open container!

Jeepwalker

Is a cocunut with a straw considered an 'open container'? ha ha

TikiX

Haha, some of the holes were approaching coconut-size when we sold it!

TikiX

Good to know about some models not having roof racks.
Yes, I’m considering going to SoCal and buying one there and then shipping it over. I lived there for 30 years and shipped my truck over when I moved. Truck was an 18 year old rust free Cali truck when I shipped it over, now it’s rusting out after just 8 years.

jordan96xj

The rust-free southwestern U.S. vehicles can be a double-edged sword. It is good that they are rust free. But they suffer from clear coat and paint degradation to a much higher degree than those in other parts of the U.S. This is going to particularly true for the roof, hood, and tops of the fenders. If this paint/clear coat is not doing its job, and moisture can get behind it, then when the vehicle is taken to a new location with moisture and salt present in the air on a routine basis, these areas are going to be prone to corrosion first. Because the body of the XJ is pressed from such thin, low quality, sheet metal, that corrosion can do a lot of damage in just a few seasons.

PatHenry

True, but it may be easier to do a rattle can paint job, or a monstaliner job on it (both of which seem to be commonly DIY jobs on XJs) or have a MAACO paint job done than fixing existing rust and rot.

Any way that you look at it, when salt is involved, it opens the door to damaging deterioration of the metal.

awg

I too live right by the sea all my adult life..Ocean st is my address

Rust is what destroys cars around here..they rust from the top down and inside out, totally unlike the USA salt road vehicles

I just went thru and repaired 4 holes in mine, over the D-plillars and B-pillars

The rust over the B-pillar had not perforated until I took to it with a die grinder..definitely from the inside out

I also took my front windscreen out and attended the seal, repairing minor surface rust

will double check the rivet holes for the roofracks, hadnt thought of that as a source of entry

the rear body at the top, obscured by the hatch has a z-shaped area which traps water, and is very prone to rust indeed..it ought to be checked and cleaned out.

I also attended the drip rails.

If you want to own an XJ in my part of the world, ZERO rust is the only acceptable situation.
I have spent hundreds of hours on vehicles cutting out rust, forming new sections, and welding them in