What is the source of the rust in the boot and passenger side floors?

[Lionelgee]

Hello All,

While working on the Discovery's brakes today I looked up under the back of the floor near the driver's side of the rear cargo door hinge. I noticed a seam of rust had developed along the low bead in the floor that runs parallel to the bumper bar. A couple of prods with the edge of a wire brush resulted in the brush passing through the floor. The bead is about 20 Centimetres long and rusted out its full length.

Do having leaks in the alpine windows cause water to get into the boot?

Does only driver's side bead get rust or will the passenger side of the bead get rust too?

On the passenger side foot well there is a plastic plug/pin near a couple of bolts. I pressed up the plastic pin and wobbled it side to side and the hole expanded - it too was rusty.

Is a fault with the front windscreen seals or maybe the plenum or cowl or scuttle the result of rust in the passenger foot well? If not the windscreen; where does the water get in to cause rust in the foot well?

Kind regards
Lionel

[Roverlord off road spares]

the rust in passenger floor can come from block air con drain tube, or from the plenum intake. When the bonnet is up, above the fire wall you will see the wiper motor on the drivers side and on the passenger side the is a blanking plate with a seal, this is where the wiper motor would go on left hand drives models. Water can run past this seal on heavy rain as the drain on the tray below cant cope fills up, water then enters the cabin. Seal with silkafex of similar.
there a couple other spots nut hose are the common water ingress spots.
block sun roof drain tubes all let water in.
rear cargo door seals let water into rear. alpine windows common to rust, I had to remove mine then weld a piece of metal in and bog and finish it.

[cripesamighty]

Lionel, go to the top of the page and select the 'Files' tab, then 'Technical Manuals' and you will see two Disco 1 Water Ingress Manuals at the bottom of page 1 and page 2. These should help.