Rust

[madlock]

I noticed something troubling the other day and am wondering how (if?) normal it may happen to be and/or if it's something I need to be concerned about.

Along the lower track for the driver's side door, I noticed a considerable amount of rust specks all over the place. It was especially heavily deposited atop the black bracket that connects the sliding door to the lower door track. Unfortunately, I made the mistake of wiping clean (for the most part) the bracket, although a considerable amount of residue remains on the frame that I left in place to show my local dealer (not the selling dealer).

To my great surprise, I was told by the servicing dealer, "That kind of rust's not covered. We'd be happy to clean it for you, but we'd have to charge you for it." I pressed to know why they wouldn't look into why a brand new vehicle would be rusting or why, given the vehicle's corrosion warranty, inspecting, cleaning, and properly coating any parts that may not have been during manufacture. I was told that the corrosion warranty only covers parts that actually "fail" due to corrosion, and a matter like this would simply be considered a "finishing defect" and, for all intents and purposes, "too bad", 300 miles and 3 weeks old notwithstanding. I asked the Service Manager whether he had seen this kind of thing on new vehicles and he said he hadn't.

I suspect I'll have better luck at the selling dealer that's more motivated by their potential CSI results; but I remain puzzled as to both whether or not this is a common phenomenon, whether or not anyone else has noticed something similar, and what, if anything, I can expect from Ford if the dealer won't respond. I'm perfectly content to wipe away the corrosion, provided it's not simply ignoring a potentially much bigger problem.

On an unrelated note, I had also noticed that the same sliding door wouldn't stay open at its fully-open position. I compared the bracket that serves as a "stop" with its mate on the other side, and noticed that it didn't seem to have the same curve to the metal and wasn't coming in contact with the door. Upon closer inspection, I noticed that it was mounted to the vehicle by two simple bolts that I could easily adjust myself. When I looked closer, it became obvious that the bracket was fractured at one of its bolt holes.

The replacement part is on its way, but I was surprised to learn that Ford normally WOULD NOT have covered this. The Service Coordinator explained that Ford WOULD cover the issue of the door not remaining open, but because "new cars aren't built broken", any broken piece like this, no matter how new or unreasonable it would be to expect the problem to have been owner or use-related, would not normally be covered. So much for the difference between "malfunctioning" and "broken". Anyway, the dealer ordered the replacement part and the repair will ultimately be pushed through, but I have to say that this has been quite the learning experience.

If anyone has seen anything similar pertaining to the rust, I'd greatly appreciate any insight or recommendations. Thanks in advance.

Edited January 27, 2010 by madlock

[REC]

Damn, you have some serious problems with dealers where you are.

The rust that you show is an issue that they should be all over getting handled - new car, new model, customer service type thing. The dealers here (two of them I've used) have been VERY helpful in getting the broken pieces replaced, taking care of the little problems that I've given them, and even trying to fix one that I not only wasn't worried about, but was self inflicted (TPMS light on).

Someone needs to get a reality check. The last time I looked, there is an 800 number on or in the owner packet. If I got even one stupid answer like "we don't cover that", I'd be on that line wanting some explanation. There are too many dealers it seems, that don't quite have a grip on reality when it comes to service.

Ford has been better than that as a rule in handling any problems I've encountered - not just with this van, but with previous vehicles as well. Further note: Most dealers now have a "customer service" person that handles BS like what you are describing. The one that we had would literally get right in your face if you didn't handle the customer and the problem. The store owner told us up front, you are empowered to do what it takes to please the customer. His GM added that if a dis-satisfied customer got to his office, you were not gonna have a good day, and it could result in termination. They were SERIOUS about customer service. When that owner sold the franchise, the new owner had the outlook and provided the service you describe. The franchise has been sold again times at least 2, as the store went down - bigtime. I watched from a distance as it spiraled in... It wasn't pretty.

The broken pieces, I'd ask for some type of explanation as to how they think you may have done this, if that is what they implied. That is just plain asinine. Mine had some plastic pieces that were broken, as well as that silly piece you show (mine didn't break but the bumper seemed to be awol. They fixed all of it, and did so with a smile, as well as calling me during the time the parts were on order to give me updates on when the delivery of the parts would be. I give them an A for that.

I believe the rust issue you show was under a 30 day/1000 mile thing. They would take it and either clean that mess up or repair/paint the area if it was required. Again, that's just not right. Mine was cleaned while I was back for other reasons (unrelated to the van) and there were NO questions and zero BS.

I honestly think the sales guy was the reason. He was excellent, and has even said that I should let them re-clean it sometime when I'm in the store. (There was a minor monsoon the night I got mine)

I have referred as many people as have asked where mine came from right back to him, and told them why as well. In a world of not so good service, the store and the sales guy are exceptions to the rule.

Service in both stores I've used has been VERY good.

I hope you have better luck soon... this is not what I'd expect.

Roland C.

Happily Transiting

Edited January 30, 2010 by REC

[madlock]

Yeah, I've had pretty crappy dealer luck, though to be fair, the dealer where I took it this time was my local dealer, not the selling dealer. Unfortunately, although it shouldn't make a difference, it does in terms of service.

I DID call the selling dealer however, in response to the door stop bracket, as the broken bracket was only a symptom, NOT the actual problem. The actual problem is that one of the two bolts (which seems to be electro-welded to the door frame during manufacture), seems to have been knocked-off during manufacture and was tack-welded VERY sloppily into place. The resulting bead and build-up caused the bracket to not rest flush against the body which both caused the stop to not function properly AND for it to fracture at the stress point when the nut was tightened. I only discovered this when the replacement was installed and didn't function properly.

The local dealer offered to send it to a body shop (they don't have one on-site), but said the fix would be to drill the frame and attach a bolt from the back. Granted, it would be a functional fix, but it pisses me off to have them drilling holes to rig-up an alternative to what should have been done properly at the factory. I then called the selling dealer (who happens to have a body shop on-site). They're 60 miles away, so I wanted to make sure one trip would be all I'd have to make to get it looked at and dropped-off. They wouldn't even commit to a loaner car despite both problems being "30-day" items.

This was in addition to the failed cruise control unit (which was successfully repaired and thankfully manifested itself during the first technician test drive), and the shorn seat frame. I swear, the guys at Otosan must have held a wrestling match inside mine as it went down the line. Atop having picked the wrong upfit package, I really kick myself in the ass for not having bought the otherwise-identical unit parked next to it. Stupid f-ing me. :(

[jenzaka]

I just finished washing my van. There are 1000's of rust spots all over the truck. Every exterior steel panel is affected along with part of the floor in the rear.

I'm sure my boss is not going to be impressed as this was a test vehicle to replace our aging fleet (120) of Astros.

BTW it only has 8,000 K and has been on the road for 6 months.

[jenzaka]

Well I took the truck to the dealer today. I must say the service was great. They gave me a drive home and they returned the truck to my driveway 4hrs later all nice and shiny.

The problem was brake dust landing and sticking to the clear coat. Apparently it is a problem they have had in the past on Crown vics. They buffed the entire truck to remove the spots. There is no other brake pad available at this time but when one is available they will try it out (no charge). In the mean time they have ordered splash guards to be installed on Monday also no charge.

If in 3 months it is covered in spots again they will clean it up again.

If your in the Niagara Region I highly recommend Brock Ford.

[isellford]

Sorry I missed your 1st post or I would have suggested that as a solution. We had that problem several years ago on F150's and had to clean almost all of the white ones. The brake dust wasn;t from your vehicls but rather rail dust from travelling on a train for an extended length of time. glad to hear about the great service. if you don't mind, I would like to pass your comments on to Ford.

Edited March 27, 2010 by isellford

[jenzaka]

Rail Dust.....wow I never thought of that.

By all means pass my comments on to Ford.

Greg

[cbeddow]

Sorry I missed your 1st post or I would have suggested that as a solution. We had that problem several years ago on F150's and had to clean almost all of the white ones. The brake dust wasn;t from your vehicls but rather rail dust from travelling on a train for an extended length of time. glad to hear about the great service. if you don't mind, I would like to pass your comments on to Ford.

I don't know about rail dust, since I took delivery of my TC in Los Angeles area-they come in by ship at Port Hyneme(sp) near by. My whole roof was covered by rust spots, which were rubbed out and clear coated by Fuller Ford in Chula Vista. They blamed it on 'industrial pollution'-is the problem with the paint/-my TC is silver.

[ncranchero]

Now I'm going to have to go out and do a close inspection of my white van. :angry:

[Mikeeshaq]

I am glad i live in Texas and not in Minnesota where i used to live, otherwise... I would do to my TC as I did back in 77...

In 1977 i bought a Honda Accord. I removed the complete interior, seats, panels, rugs/mats everything. Brought it down to a rust proofer and said I made it easy for you to spray tar all over everywhere and gave him an extra $20. When it was hauled away to some charity 25 years later [it was garaged alot] there were only one place where interior rust ate thru to the outside

[jpupho]

I noticed something troubling the other day and am wondering how (if?) normal it may happen to be and/or if it's something I need to be concerned about.

Along the lower track for the driver's side door, I noticed a considerable amount of rust specks all over the place. It was especially heavily deposited atop the black bracket that connects the sliding door to the lower door track. Unfortunately, I made the mistake of wiping clean (for the most part) the bracket, although a considerable amount of residue remains on the frame that I left in place to show my local dealer (not the selling dealer).

To my great surprise, I was told by the servicing dealer, "That kind of rust's not covered. We'd be happy to clean it for you, but we'd have to charge you for it." I pressed to know why they wouldn't look into why a brand new vehicle would be rusting or why, given the vehicle's corrosion warranty, inspecting, cleaning, and properly coating any parts that may not have been during manufacture. I was told that the corrosion warranty only covers parts that actually "fail" due to corrosion, and a matter like this would simply be considered a "finishing defect" and, for all intents and purposes, "too bad", 300 miles and 3 weeks old notwithstanding. I asked the Service Manager whether he had seen this kind of thing on new vehicles and he said he hadn't.

I suspect I'll have better luck at the selling dealer that's more motivated by their potential CSI results; but I remain puzzled as to both whether or not this is a common phenomenon, whether or not anyone else has noticed something similar, and what, if anything, I can expect from Ford if the dealer won't respond. I'm perfectly content to wipe away the corrosion, provided it's not simply ignoring a potentially much bigger problem.

On an unrelated note, I had also noticed that the same sliding door wouldn't stay open at its fully-open position. I compared the bracket that serves as a "stop" with its mate on the other side, and noticed that it didn't seem to have the same curve to the metal and wasn't coming in contact with the door. Upon closer inspection, I noticed that it was mounted to the vehicle by two simple bolts that I could easily adjust myself. When I looked closer, it became obvious that the bracket was fractured at one of its bolt holes.

The replacement part is on its way, but I was surprised to learn that Ford normally WOULD NOT have covered this. The Service Coordinator explained that Ford WOULD cover the issue of the door not remaining open, but because "new cars aren't built broken", any broken piece like this, no matter how new or unreasonable it would be to expect the problem to have been owner or use-related, would not normally be covered. So much for the difference between "malfunctioning" and "broken". Anyway, the dealer ordered the replacement part and the repair will ultimately be pushed through, but I have to say that this has been quite the learning experience.

If anyone has seen anything similar pertaining to the rust, I'd greatly appreciate any insight or recommendations. Thanks in advance.

[jpupho]

I had the same problem with the rust, my dealer sanded and repainted the section. I think the rust is from another source, not from the TC itself, specks of metal land in this spot and get rusty, I will be keeping that area clean, you can compound the spots that may take care of your problem. Some post have said break dust, or rail road dust, whatever keep that section clean,hope that solves your problem, because the TC is a great van

Edited January 1, 2011 by jpupho

[hoot]

I noticed something troubling the other day and am wondering how (if?) normal it may happen to be and/or if it's something I need to be concerned about.

Along the lower track for the driver's side door, I noticed a considerable amount of rust specks all over the place. It was especially heavily deposited atop the black bracket that connects the sliding door to the lower door track. Unfortunately, I made the mistake of wiping clean (for the most part) the bracket, although a considerable amount of residue remains on the frame that I left in place to show my local dealer (not the selling dealer).

To my great surprise, I was told by the servicing dealer, "That kind of rust's not covered. We'd be happy to clean it for you, but we'd have to charge you for it." I pressed to know why they wouldn't look into why a brand new vehicle would be rusting or why, given the vehicle's corrosion warranty, inspecting, cleaning, and properly coating any parts that may not have been during manufacture. I was told that the corrosion warranty only covers parts that actually "fail" due to corrosion, and a matter like this would simply be considered a "finishing defect" and, for all intents and purposes, "too bad", 300 miles and 3 weeks old notwithstanding. I asked the Service Manager whether he had seen this kind of thing on new vehicles and he said he hadn't.

I suspect I'll have better luck at the selling dealer that's more motivated by their potential CSI results; but I remain puzzled as to both whether or not this is a common phenomenon, whether or not anyone else has noticed something similar, and what, if anything, I can expect from Ford if the dealer won't respond. I'm perfectly content to wipe away the corrosion, provided it's not simply ignoring a potentially much bigger problem.

On an unrelated note, I had also noticed that the same sliding door wouldn't stay open at its fully-open position. I compared the bracket that serves as a "stop" with its mate on the other side, and noticed that it didn't seem to have the same curve to the metal and wasn't coming in contact with the door. Upon closer inspection, I noticed that it was mounted to the vehicle by two simple bolts that I could easily adjust myself. When I looked closer, it became obvious that the bracket was fractured at one of its bolt holes.

The replacement part is on its way, but I was surprised to learn that Ford normally WOULD NOT have covered this. The Service Coordinator explained that Ford WOULD cover the issue of the door not remaining open, but because "new cars aren't built broken", any broken piece like this, no matter how new or unreasonable it would be to expect the problem to have been owner or use-related, would not normally be covered. So much for the difference between "malfunctioning" and "broken". Anyway, the dealer ordered the replacement part and the repair will ultimately be pushed through, but I have to say that this has been quite the learning experience.

If anyone has seen anything similar pertaining to the rust, I'd greatly appreciate any insight or recommendations. Thanks in advance.

[hoot]

i have a couple of rock chips on the front cowl area of the roof and it looks like they have formed a little rust. you have to wonder if these vans were undercoated. these vans have a ten year history in europe so i wonder if this has not come up before there, or it is something just with the ones brought over here. i think i'll use a little something to scrap the timy spots of rust away and use one of the little bottles of touch up to cover it, but it seems like this should not have happened!