Rust Issues

[BarrelProofMav]

That is a bummer. I plan on hitting all the seams with POR-15. If you haven’t heard of it, it’s worth a look. Pricey but effective. Just keep it away from stuff you may wish to take apart some day. https://por15.com/

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[Dturano547]

The last few years Ford f150 have taken heat for being rusty on delivery. It's a problem industry wide... I work in the auto body industry, new metals are mixed and mostly garbage. When manufacturers use aluminum on panels they run the risk of having primer adhesion issues, Ford liftgates and hoods, as well as Chrysler hoods. One metal may not rust but your paint will peel... Like some stated you have a warranty, I would bring it to the dealer and have it documented since it's so new to prevent future claims. They may not address it at this point. I understand my dealer won't put my Maverick up on a lift for me at delivery but I plan to crawl underneath before signing, I don't want any transport issues to cause me a headache on a vehicle purchasing not leasing. Leased I wouldn't care about this or much but since I'm purchasing the dealer will be documenting my eagle eye inspection before I pull off. I realize it's not a six figure keeping up with Jones monster but certain quality control things are unacceptable at any price point.

In all honesty most Maverick buyers are so excited to receive the new truck they sign smile and head out on the highway...

 

[vezpa]

I took the plastic rocker trim and wheel well liners off and painted them with a nice coat of black paint. A week later I took the truck in and had the entire thing undercoated and rust-proffed. Every inch. Those pinch welds are going to rust.

Someone lifted that truck on those welds which is a common place for mechanics to lift unibody cars. I complained to our mechanics for this all the time. Did you take it in for service/oil change yet?

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[Espeer]

Yep Ford's are known for their rust. You think its bad now, give it a few years.

I'd only had cars from the Midwest or New England. Rust was inevitable without extreme measures.

Moved to Virginia and bought a new focus 10 years ago. 180k miles and there is basically no rust, even underneath. It gets washed once or twice a year and that's it. Drive on salted roads a couple of times per year. As opposed to every day for 4 months. I expect my maverick to be just as good...

 

[Paulyz]

Was looking under my Maverick today and found some really concerning rust in the pinch welds below the rocker panels. I’ve had it for less than a week and less than 500 miles. Taking it in on Thursday to hopefully get it repaired under warrantee.

Yeah no excuse for rust so quickly. Why I'm getting an underbody treatment when mine arrives. I'll be looking first to see if there is any rust.

 

[stick]

That is not 'acceptable' as some have indicated. Rust at that point will move up take out the rocker panel in a few years. And if it rust that quick, it will spread fast too. Good catch by the way! glad my hybrid is delayed, will be spraying cosmoline rp-342 like on my jeep. I was going to have it undercoated until I read that the coating harden and crack, trapping in water and causing rust. I pretty much sprayed anything under that rusts, including suspension and steering components. Just hate seeing rust even on components that dont really cause issues. As soon as my truck arrives, this stuff will be applied EVERYWHERE underneath.

 

[Shakesbear]

Must really suck to live up north. I've had many Ford's here in Texas and never had any rust issues. The underside of my sons 2010 F150 looks almost new. Of course, they don't salt any roads down here either

 

[FakeCowboy]

That is not 'acceptable' as some have indicated. Rust at that point will move up take out the rocker panel in a few years. And if it rust that quick, it will spread fast too. Good catch by the way! glad my hybrid is delayed, will be spraying cosmoline rp-342 like on my jeep. I was going to have it undercoated until I read that the coating harden and crack, trapping in water and causing rust. I pretty much sprayed anything under that rusts, including suspension and steering components. Just hate seeing rust even on components that dont really cause issues. As soon as my truck arrives, this stuff will be applied EVERYWHERE underneath.

You will find this on every single car at this price point. Remember, even if you paid 37k for your Lariat, the sheet metal is still made for a 20k price point, the mild grade steel exhaust is still made for the 20k price point, the cast iron steering knuckles are still made for the 20k price point. Blame rising steel prices and manufacturers seeking out cheaper options for steel, aka recycled Chinese garbage steel, mild grade steel on the mufflers and every other component where Ford needed their suppliers to shave pennies to get the truck to the 20k price point.

The pinch weld rust is because the tech probably didn't use rubber pads on their lift points when they put the vehicle in the air for the PDI. We already know that the 20k price point paint job on the Maverick damages if you look at it the wrong way so clearly putting metal lift points on the pinch welds are going to damage the paint and primer and reveal low carbon content mild grade steel which will oxidize quickly.

 

[Fredvon4]

Only alarming thing I see is evidence that this new type paint is not very durable in high impact areas

My plan...MUD flaps
If I find minor areas like this rocker pinch weld area I will spend 3 mins with rotary wire brush, 5 min masking, and 5 seconds spraying on one of the 50 good protection products for this

I am much more concerned with the photos showing rocks and mud inside the tail light wheel well cavities. Once it get mine if ever I will address a way to block that road spray in there.

Lastly I always trade low mileage new vehicles away before the factory warranty is up
This too will be a non long term keeper

 

[KevCuRaoi]

Was looking under my Maverick today and found some really concerning rust in the pinch welds below the rocker panels. I’ve had it for less than a week and less than 500 miles. Taking it in on Thursday to hopefully get it repaired under warrantee.

Underbody surface rust is not warrantable.

 

[stick]

That is a bummer. I plan on hitting all the seams with POR-15. If you haven’t heard of it, it’s worth a look. Pricey but effective. Just keep it away from stuff you may wish to take apart some day. https://por15.com/

be careful with POR-15 as designed to work with rust present. No rust, minimal bond. On this position, most likely will come off as easy as the paint.

 

[Camlt12010]

Was looking under my Maverick today and found some really concerning rust in the pinch welds below the rocker panels. I’ve had it for less than a week and less than 500 miles. Taking it in on Thursday to hopefully get it repaired under warrantee.

Did they fix?I noticed the same with mine. 7 months old 1700 miles. Also around holes on floor pan.

 

[Vols44]

The only place I remember seeing rust on my Ranger, Fusion and Edge was the muffler since it is exposed metal that endures extreme temperatures.

I appreciate your maverick observations OP. I will be checking out my truck for an ever growing list of things in Salina, KS and my garage.

 

[troynm]

One advantage to living in the great southwest. OTOH we haven't had any rain this year that I recall and our forests are burning up. I suppose I need to worry about ash deposits.

 

[Camlt12010]

Was looking under my Maverick today and found some really concerning rust in the pinch welds below the rocker panels. I’ve had it for less than a week and less than 500 miles. Taking it in on Thursday to hopefully get it repaired under warrantee.

What did Ford say? Did you take it ? Have concerning rust on the underneath of mine too.

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