Rust is the W116's defining structural threat, concentrated in rocker panels, jack points, and the firewall, and worst on cars that lived near the ocean or in salt-belt states. Rocker replacement is described as a big but doable weld job with panels available from Germany (roughly $900 shipped via MBCC), while firewall repair is more involved.
Rust: rockers, jack points, firewall, and salt/coastal cars
Mercedes-Benz S-Class (W116) · buying