Rust on roof bordering windshield

[RSM]

My 2023, 2 spots I will be trying to fix

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[SPIJG]

Ford has really failed with corrosion protection in this roof area. I had a ~1/16" chip occur probably from a stone some time between last summer and this spring. One salty Michigan winter turned that into 3/4" diameter of rust subtly traveling under the paint. Without close inspection it wasn't obvious, and unfortunately I usually only do a thorough inspection of my vehicles once a year in the summer. I have never had a small chip rust so badly and so quickly with any other vehicle. Hopefully the OP can get his handled under warranty.

Thank you, for your input!

 

[gjallen3]

Unfortunately, there have been a few other posts from members having the same issue. One less serious than this post and another one worse. The member with the big bad bubbly spot was having issues with his dealer if I recall correctly.

After reading those threads I put some gorilla tape on that gap. Could cause problems instead of prevent? Anyway, I’m going to peel it off soon. BTW, I used to have tape holding my eyeglasses together. Genuine Nerd…

I don't want to be sticking any gorilla tape there, but it does appear that at least one explanation could be stone chips that got out of control and water probably channels into the space between the windshield and the roof and sits there for a while. As a precaution against stone chips in that area, I'm thinking of maybe putting a rubber hose the length of the windshield with a diameter wide enough to create a snug fit and just high enough to go a little over the roof protecting the crease from flying rocks.

 

[SPIJG]

My 2023, 2 spots I will be trying to fix

So what are you going to do?

 

[Bob The Builder]

That looks like a vicious stone chip that never got addressed. On the edges I see old pitting with paint over it. That needed to be taken care of right after it happened and it needed to be fixed right not just touch up paint put on over rust.

As a veteran of living in the rust capital of the world, these things need to be taken care of immediately and it will become a losing battle is not fought correctly.

 

[OleFordGuy]

Not sure how to treat this and living on the salt water doesn't help, so looking for a remedy to repair/fix this....

Holy Smokes, that whole roof is a disaster, especially on a 2 year old truck. Ford should fix that under rust warranty, if they give you a hard time at a reputable dealer I would escalate it up the chain at Ford or whatever you have to do. That won’t be a cheap fix imo

 

[SPIJG]

That looks like a vicious stone chip that never got addressed. On the edges I see old pitting with paint over it. That needed to be taken care of right after it happened and it needed to be fixed right not just touch up paint put on over rust.

As a veteran of living in the rust capital of the world, these things need to be taken care of immediately and it will become a losing battle is not fought correctly.

Wow, funny you mention that because NOTHING has been done to it, my bad for that, but no touch up paint, so now what?

 

[SPIJG]

Holy Smokes, that whole roof is a disaster, especially on a 2 year old truck. Ford should fix that under rust warranty, if they give you a hard time at a reputable dealer I would escalate it up the chain at Ford or whatever you have to do. That won’t be a cheap fix imo

Thank you!

 

[Darthie]

Must have started with stone chips. Gotta watch for that now so it can be touched up right away.

 

[Edge Haley]

The roof is steel (not aluminum) and the tiny spots of rust and bubble on the roof (2 OR 3 inches behind the big wound) would highly suggest to me that it is a thin coat of paint that was penetrated with rust, not rock damage. I wouldn't waste time on an outside party until FORD dealer approves repair under warranty.

I do a lot of body work as a hobby and that is not an easy repair. Certainly, looks like the interior roof liner, windshield, all rubber trim, etc will have to be removed to fix/patch/replace. Rust could probably be patched but I'd look for a pro to fix it....but Ford warranty may require them to fix since it is probably a warranty issue. If patched the entire headliner will probably need to be replaced. There are some amazing glues that make patching easier without heat..But that rust has to come out first....If covered under warranty I'd encourage the dealer for extended warranty against other future rust. Good Luck!

Hope you report results.

The below may be your worst problem under Fords's warranty:
Paint is covered under the New Vehicle Limited Warranty of 3 years or 36,000 miles, whichever occurs first. This warranty provides coverage for defects in workmanship and material. If you have a paint-related concern, your Ford Dealer can determine if it is covered under warranty.

A good dealer and Ford should cover repairs, but you screwed up by not reporting it when is started showing!

 

[Art Vandelay]

Corrosion warranty is 5 years/unlimited miles for rust-through perforation. Take it to the dealer and find out if it's covered. It won't cost anything to have them check it out.

Terrific suggestion, before going crazy trying to pull windshield, etc. Thanks!
jg

Please report back and let us know what the dealership says.

 

[Bob The Builder]

Wow, funny you mention that because NOTHING has been done to it, my bad for that, but no touch up paint, so now what?

Fair enough. So now what?

Firstly, I would pursue Ford to fix it under warranty. As others have stated that is a hard fix in a bad spot.

Secondly, if #1 does not work out, I would take it to a shop and have it professionally done. The truck is still new enough and valuable enough to have the work done right. Not going to be cheap but what are the alternatives really?

I had that type of problem right in that same area all the time with my Rangers. Interstate driving in winter up here destroys vehicles well before their time. That is why I always bought black Rangers even though they were not my favorite color as black is easy to blend. Pretty from a far, but far from pretty I would always say. Vinyl wrap and plasti-dip can also be your friend. I painted my black front bumper in rock guard paint.

Best of luck to you and please keep us informed on how things work out for you.

 

[MiMav]

Must have started with stone chips. Gotta watch for that now so it can be touched up right away.

I agree. I think you have about 10 minutes to touch it up before rust sets in...

Based on what's been reported here and my own experience, stone chips go bad quickly on the Maverick roof, unlike anything I've seen on other vehicles. My 12 year old Escape gets lots of chips and I try to touch them up, but even ones that have been neglected never rusted.

 

[Cancunbadlands]

That needs a pro body shop job!

 

[Hansolo]

They will say it was caused by a rock chip therefore it’s not covered under warranty.

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