NHTSA Complaint #10245275 — 2004 FORD F-150

A RUST AND PANEL PERFORATION ON THE RIGHT BOX OUTER OF 2004 FORD F-150'S. RUST DEVELOPS UNDER THE PAINT ON THE RIGHT BOX OUTER PANEL BEHIND THE RIGHT REAR WHEEL OPENING AND ABOUT AT THE CENTER FOR HEIGHT OF THE PANEL. THIS HAS HAPPENED ON SEVERAL TRUCKS OF FRIENDS AS WELL AS MY TRUCK. THE DEALERS ARE SAYING IT IS BECAUSE THERE IS A BRACE WELDED TO THE PANEL DURING PRODUCTION AND THE WELD ID THE ROOT OF THE RUST. FORD IS SAYING THAT THEY HAVE NO RESPONSIBILITY AND WON'T HELP TO COVER THE COST OF REPAIR. AS A RETIRED ENGINEER FROM ANOTHER MANUFACTURER AND ALSO HAVING WORKED FOR THE OTHER OF THE BIG THREE, I KNOW THAT WELDING DESTROYS THE RUST PREVENTABLE ON THE SHEET METAL. THE WELD PROCESS FLOWS GALVANIZE AWAY FROM THE WELD AREA AND THEN HELPS TO PRECIPITATE THE RUST TO FORM. THE TRUCKS HAVE ALL HAD NO PAINT DAMAGE OR ACCIDENTS IN THE AREA OF THE RUST FORMING. BUBBLES APPEAR UNDER WHAT LOOKS LIKE GOOD SOLID PAINT AND THEN BREAKS THROUGH AND SHOWS RUSTED METAL. WITH THE NUMBER OF TRUCKS HAVING THE SAME ISSUE IT LOOKS TO BE A SYSTEMIC ISSUE FROM THE MANUFACTURING PROCESS. THE OTHER TWO DOMESTIC MANUFACTURERS WILL NOT WELD ON WHAT IS KNOWN AS A CLASS A OUTER PANEL SURFACE. A CUSTOMER?S LINE OF SIGHT WALKING UP TO A VEHICLE IS CONSIDERED TO BE CLASS A SURFACE. THERE SHOULD NOT ANY BE WELDS ON IT AND LITTLE OR NO METAL FINISH. THAT, METAL FINISHING, ALSO WOULD REMOVE THE RUST PROTECTING GALVANIZE. ANOTHER CONCERN IS THAT SOME STATES HAVE ANNUAL INSPECTIONS THAT WOULD CAUSE THIS TO HAVE TO BE REPAIRED. THE OWNER WOULD BE STUCK WITH THIS COST THROUGH NO FAULT OF HIS OR HER OWN. *TR