I reported this problem 3 months after I purchase the vehicle Ford F150. I fought with dealer for six months later, I had to have a welding expert with a report explaining the stress areas in which these manual welds were put over the top of a robotic weld after the frame was e coded therefore rust is now very evident and I'm concerned that its rusting from the inside of the tube frame located at stress points above the drive axles, on the main frame, Ford's response was it's not a problem, therefore if I am in a accident, I hope my wife will sue Ford and the Dealer or buyer beware.....

I understand that this 2015 frame had several mfg problems, however Ford will not resolve the issue.

Apparently the new Ford F150 trucks have a serious problem with with rust and corrosion on their brand new trucks because there are customer complaints abound all over the internet and YouTube. I've had my truck about 6 months before noticing significant amounts of rust all over the frame of the truck as well as several other steel, metal and aluminum parts underneath the truck. From talking to various Ford dealers and body shops it appears there are multiple issues at play here and below I will list a few of the problems that I am having and unfortunately Ford has yet to address my situation at all and have not forthrightly dealt with this situation for any of its customers.

1. Ford Truck E Coating Failure. This is supposedly a feature that Ford sells but if its supposed to prevent rust it either doesn't work very well or they do not apply it to all the parts before assembly.

2. Ford raves about their new aluminum body for its strength and lightness but they haven't done enough research and development and how it works with the other steel parts. When aluminum and steel are connected the possibility for oxidation is greater and this leads to premature corrosion because aluminum is a metal that is known to corrode.

3. There looks to be manual repair welds on top of robotic welds. Not sure why this would be necessary unless they know they are having problems during the manufacturing process and have decided to staff manpower to come behind the automated assembly process and attempt to repair new Ford Trucks before they ship them to be sold to unwitting consumers.

4. Ford has approved poor quality welds that produced blow holes and cracks in the frame. These cracks and holes add unnecessary stress to the metal frame.

5. Re-welding joints that have been welded before only accelerates the corrosion and rust problem that Ford is having with its 2015, 2016 and 2017 models of the Ford F150.

6. My truck was repaired by Ford Trucks before I purchased it. Ford is selling trucks that have been repaired as if they were new. This is a major problem because they are not being forthright about the quality or lack thereof with their product. Disappointment can't even begin to describe my sentiments at this point. I'm a longtime Ford customer of their cars as well as trucks and I feel betrayed by the process and the way they are responding to this problem. This is my 4th new Ford F150 that I have purchased from Ford and now I'm being forced by Ford to shop other brands as a result of their lack of transparency and horrendous customer service.

7. Ford Engineering needs to get involved and help direct its current and future customers about what steps to take to remedy this situation. They also need to come up with a design that takes all of this into account for the Ford F150 moving forward. If this is a problem they are having with the bulk of the new Ford Trucks then Ford needs to call for a recall of the effected model year Ford F150 trucks.

2015 F-150 XLT Super Cab 4x4, (New - Nov 24th 2015) (Only 3,100 miles on it) FACTORY REPAIRED Unit SOLD AS NEW!

About March 10th, 2015 / I send (Text) a photo’s to my sales person (Brandy Crothers – Gurley Leep, South bend IN) with a 6’ rust line down my driveway, after the truck was sitting for two weeks in my driveway, and with what I found!

This was noticed after a two week long work trip that it had been sitting in my driveway, and I had noticed it after moving the truck when I returned and it was coming from my new truck. When I picked the truck up I did not notice this problem, I believe it was masked at that time. After further review, looking under my new truck photos, showed that manual repair welds over the top of robotic welds to the steel frame inside the rear tire (wheel well – Behind the tire) were rusty (Corrosion) The fact that the welds were of very poor quality and show blow holes, cracks, and added stressed metal.

4 of these manual welds are on the passenger side wheel well. 2 of these manual welds are on the driver side wheel well.

Other Items noted, were that the rear end and axles were also rusty with no corrosion coating on them. Also exhaust hangers, U joints, also show excessive rust. • I have been to the Dealership four times – without a plan of action or repair. • I have called and talked to Ford regional Customer Service Rep - and was told the dealer will repair / but could not tell me how? ( Asked for Manager to speak with) • I had to call her customer service manager – and after a week later, “Heather” (Ford Customer Service Supervisor) called back and told me that she could not share how the dealer would repair and that Ford would not buy back the truck. • I offered to drive the truck to Detroit to the engineering group to investigate this and wanted to work to resolve the problem, I was told they did not have anyone that handles this? WHAT is that response? Don’t’ they set the standards to build trucks? • Another visit to the dealership – Jimmie Fogus / told me that they did not know how to repair without replacing the frame, and then rebuilding my truck from original these parts and about 4 weeks labor? They (Dealer) has never done this before / nor could re-assure that there would not be any further problems. • My Sales Person was told to stay out of the conversation at this point. • Dealership Operations Manager Scott Pharr – is now trying to see what he can do / this was one week ago with no reply yet. May 5th /May 6th

Other Issues; Rear Window – was installed with the bottom out further than spec, also shows delamination of the glass in the bottom side passenger side. – Dealer service dept. (Jimmie Fogus – Service Advisor, Gurley Leep / no longer there) had this approved under warranty. It was not done until we found out what Ford was willing to do about the weld problems? They told me that it was not a concern and that the dealer would repair it. I am not allowing the dealer to repair without direction from FORD Engineering, and until I have the repair method, standards, and welding spec for this, due to safety concerns and long term stresses on the metal? Experts are telling me that by re-welding three times in the same area and not able to get to the inside of a tube frame that has the original poor welds, will only accelerate the current corrosion and rusting further. Keep in mind that currently manual weld on top of the robotic welds that have corrosion.

At this point, and no response in the last three months from FORD or the Dealer, I will focus my efforts in making a claim of – Michigan Lemon Law.

As this was a repaired truck before I purchased it, I am asking for a complete new unit replacement or complete buy back including all expenses related to the purchase of / and execution of this resolution.

This is a $52,000 – Ford 2015, XLT 4x4 4dr F-150 Used Truck that was sold as new.

I feel that Ford Customer Service (Rep and Manager) was not concerned with the end customer nor that the people in my circle of influence seen this quality allowed.

Very Disappointed in Ford

This a copy of the email I have just recently sent to the salesperson at the Ford dealership. The unit has 1550 Kms 963 miles for you south of the border. and it is already rusting....! Really ...this not acceptable for a brand new vehicle. The truck box was not sealed to the truck bed as well and dust pours in on dusty roads. I can fix that with a tube of good silicone..but the quality needs to be better than that...far better! Tie rods and differential are rusting already....! Critical steering components and no proper corrosion control... Hears the letter....feel free to copy and paste to if you feel like it...

I am sending a email with pictures which I consider unacceptable quality and workmanship of my recent F150 purchase. The unit only has 1550 kms. The rear deferential has considerable rust already. I would have hoped a truck with a MSRP of 49,000 plus would have a higher standard of paint/rust/corrosion control. Same with critical steering components which are expierencing the same premature corrosion problems. Also the factory failed to seal the truck box to the truck leaving gaps around the entire box. Now dust, dirt and water can enter the truck box and cause anything stored in the box to become dirty/damaged. I wish to continue to be a proud owner of a Ford truck.... But these defects are maybe a oversight in manufacturing process I hope and they can be dealt with in a professional and expedient manner. As i expressed in the letter I hope to continue to be a proud Ford owner and these problems can be easily resolved....I could do it myself with pricey frame paint but Ford needs to stand by their product and keep there customers with safe,reliable and quality vehicles. Like most of you this is a new truck and I didn't crack my kids piggy bank to buy it... I will be known as Crowsnest....referring to a beautiful area in southern Alberta where I love to hike, explore, ride our Yamaha Rhino, fish and relax!! Love to bush-walk in the forests !! A Day In The Mountains Is A Day Well Spent.......... Cheers Crowsnest