NHTSA Complaint #10513310 — 2010 FORD F-350 SD

DURING ITS WARRANTY PERIOD, THE VEHICLE EXHIBITED RUST AT LOAD-BEARING AREAS OF SEVERAL CROSSMEMBERS WHICH SUPPORT THE PICKUP BED. THE RUST OCCURS EXCLUSIVELY BETWEEN THE STAMPED STEEL CROSSMEMBER ITSELF AND A STAMPED STEEL REINFORCING PLATE WHICH IS SPOT-WELDED TO EACH CROSSMEMBER WHERE IT INTERSECTS AND MAKES LOAD-BEARING CONTACT WITH THE VEHICLE'S FRAME. BECAUSE THE RUST AND ANY MOISTURE, SALT, ETC. ARE CAPTIVE BENEATH THE REINFORCING PLATE, RUST IS CONCEALED FROM VIEW UNTIL IT PROCEEDS BEYOND THE PERIPHERY OF EACH PLATE. THIS MAKES IT DIFFICULT TO KNOW THE DEPTH TO WHICH RUST HAS PENETRATED EACH CROSSMEMBER. AS THE LOAD-BEARING PORTIONS OF THE PICKUP BED CROSSMEMBERS ARE WEAKENED BY RUST, THE VEHICLE'S RATED PAYLOAD CAPACITY IS COMPROMISED ACCORDINGLY AND THE POTENTIAL FOR CROSSMEMBERS TO COLLAPSE AT OR BELOW THE VEHICLE'S RATED PAYLOAD CAPACITY BECOMES A CONCERN. COLLAPSE OF THE CROSSMEMBERS WHICH SUPPORT THE PICKUP BED AND ITS PAYLOAD COULD RESULT IN SUDDEN DESTABILIZATION OF THE PAYLOAD AND THE VEHICLE, LEADING TO LOSS OF CONTROL OF THE VEHICLE AND POSSIBLY A CRASH. FURTHER CONCERN IS THAT THE UPPERMOST PORTION OF THE FUEL TANK IN THIS VEHICLE (WITH GASOLINE ENGINE) IS PROTECTED BY A CLEARANCE BETWEEN IT AND THE UNDERSIDE OF THE PICKUP BED, AS MAINTAINED BY THE HEIGHT OF THE CROSSMEMBERS. EXPOSED ATOP THE FUEL TANK IS THE EXTERIOR PORTION OF THE FUEL TANK SENDER ASSEMBLY AND ITS FITTINGS, COMPRISED OF A PRESSURIZED FUEL LINE AND CORRESPONDING FUEL RETURN LINE, FUEL VAPOR LINES, AND ELECTRICAL POWER TO THE FUEL PUMP. THERE IS CONCERN THAT THE UNDERSIDE OF THE PICKUP BED MAY MAKE DAMAGING CONTACT WITH THESE FITTINGS SHOULD A COLLAPSE OF ITS CROSSMEMBERS OCCUR. THE VEHICLE HAS BEEN SURRENDERED TWICE FOR WARRANTY REVIEW, EACH DENIED. A THIRD ATTEMPT AT REPAIR IS PRESENTLY IN NEGOTIATION WITH FORD MOTOR COMPANY IN AN OPEN CASE, CUSTOMER TO ASSUME HALF OF ALL COSTS. *TR