Sponsored

Rust on roof bordering windshield

Tbone289

2.0L EcoBoost
Well-known member
First Name
Terry
Joined
Jul 18, 2024
Threads
0
Messages
2,135
Reaction score
3,647
Location
MO
Vehicle(s)
'24 Mav FX4, '12 Focus SE Sport, '01 Focus ZX3, '00 Jeep XJ, '67 Bronco
Engine
2.0L EcoBoost
The windshield will need to be removed, then all of the rust. If the metal is near perforation, new metal will need to be welded in. If not, it will need to be treated and filled, then painted. The preference would be new metal.

What is concerning is all the pitting/bubbling you seem to have on the top under the paint.
 
Last edited:

Aleks

2.5L Hybrid
Well-known member
First Name
Aleks
Joined
Apr 30, 2025
Threads
3
Messages
247
Reaction score
411
Location
West Coast
Vehicle(s)
2025 Maverick AWD Hybrid - Lariat
Engine
2.5L Hybrid
What is concerning is all the pitting you seem to have on the top under the paint.
I thought that was condensation on first glance, if its not that whole roof should be sanded down to bare metal and coated with some kind of rust converter/preventer and repainted to make sure.
 

Sponsored

Tbone289

2.0L EcoBoost
Well-known member
First Name
Terry
Joined
Jul 18, 2024
Threads
0
Messages
2,135
Reaction score
3,647
Location
MO
Vehicle(s)
'24 Mav FX4, '12 Focus SE Sport, '01 Focus ZX3, '00 Jeep XJ, '67 Bronco
Engine
2.0L EcoBoost
I thought that was condensation on first glance, if its not that whole roof should be sanded down to bare metal and coated with some kind of rust converter/preventer and repainted to make sure.
You have a good point there, and I didn't consider condensation as a possibility. Those pitted/bubbled spots look an awful lot like the ones around the rusted area though...
 
Last edited:

Joester

2.0L EcoBoost
Well-known member
First Name
Joe
Joined
Jun 28, 2023
Threads
18
Messages
251
Reaction score
324
Location
UPSTATE NY
Vehicle(s)
2022 Maverick ECO, FX4, 4K, 2023 Bronco Sport, 2024 Escape Red Line
Engine
2.0L EcoBoost
Yikes! on a 2 year old truck?
 

Aleks

2.5L Hybrid
Well-known member
First Name
Aleks
Joined
Apr 30, 2025
Threads
3
Messages
247
Reaction score
411
Location
West Coast
Vehicle(s)
2025 Maverick AWD Hybrid - Lariat
Engine
2.5L Hybrid
You have a good point there, and I didn't consider condensation as a possibility. Those pitted spots look an awful lot like the pitting around the rusted area though...
I think that unfortunately you're right it does look like rust bubbles, but to repaint that roof properly is a drop in the bucket if you're already taking out that windshield and welding in a new patch.
 
Sponsored

usedtobef150

2.0L EcoBoost
Member
Joined
Jun 19, 2026
Threads
0
Messages
5
Reaction score
3
Location
canada
Vehicle(s)
lobo
Engine
2.0L EcoBoost
would that be covered under rust perforation warranty being a 2 year truck?

I wonder if it stemmed from some damage, a really bad rock chip or a manufacturing defect. Of course living by the salt doesnt help but that's extreme.
 
OP
OP

SPIJG

2.5L Hybrid
Well-known member
First Name
John
Joined
Mar 28, 2024
Threads
1
Messages
52
Reaction score
42
Location
South Padre Island, Texas
Vehicle(s)
2024 Maverick XLT Hybrid
Engine
2.5L Hybrid
would that be covered under rust perforation warranty being a 2 year truck?

I wonder if it stemmed from some damage, a really bad rock chip or a manufacturing defect. Of course living by the salt doesnt help but that's extreme.
Thanks, not sure about warranties, but thanks for the input...
 

BK007

2.0L EcoBoost
Well-known member
First Name
BK007
Joined
Mar 27, 2026
Threads
13
Messages
246
Reaction score
648
Location
OH
Vehicle(s)
2024 Ford Maverick Lariat Tremor
Engine
2.0L EcoBoost
Not sure how to treat this and living on the salt water doesn't help, so looking for a remedy to repair/fix this....

Maverick roof rust.webp
Man, that is nasty for a 2024. Any chance you can drop a zoomed-out picture of the panel? It's hard to tell exactly where on the truck this is at. If you are still under your 3yr/36k bumper-to-bumper warranty, get that straight to the dealer before it turns into a major fight.
 
OP
OP

SPIJG

2.5L Hybrid
Well-known member
First Name
John
Joined
Mar 28, 2024
Threads
1
Messages
52
Reaction score
42
Location
South Padre Island, Texas
Vehicle(s)
2024 Maverick XLT Hybrid
Engine
2.5L Hybrid
Man, that is nasty for a 2024. Any chance you can drop a zoomed-out picture of the panel? It's hard to tell exactly where on the truck this is at. If you are still under your 3yr/36k bumper-to-bumper warranty, get that straight to the dealer before it turns into a major fight.
I will take another pic at lunch so you can see the exact location of the rust. Unfortunately, 44,000 miles on the truck
Sponsored

 
 







Top