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Rusted Axle, Drive Shaft and Exhaust System on 2023

as a Canadian living in Quebec where salt is spread on the roads, and someone who works for a dealership, that looks completely normal to me, every car we receive from the manufacture (Japan) looks like that,
Even brand new ? That seems ridiculous i live in Pennsylvania US and a brand new vehicle never driven on the road shouldn't look like that
 
Even brand new ? That seems ridiculous i live in Pennsylvania US and a brand new vehicle never driven on the road shouldn't look like that
Yep even new, remember most of our trucks have been sitting waiting for chips/components plus parts ordered for trucks that couldn't go out, things are gonna get rusty
 
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I purchased a 2023 Tremor last week. Got it home and found the entire undercarriage was rusted out. I should have caught it before purchasing but who thinks the undercarriage is rusted on a brand new vehicle. Plus, I bought it at night and didn’t see it. The dealer is working with me and Ford Corp to come up with a solution. I’m not happy about it and concerned that it is greater than I see.

The dealer did tell me that Ford stopped coating the drive shaft and axles so it’s not unusual to see some rust but mine is worse than they have ever seen. I questioned how it made it out of the factory and passed a dealer PDI with this level of rust and pitting. of course, they have no answer. The pics look like the parts have been sitting outside in the snow and elements for years.

Has anyone had this issue with a new Ford? Does anyone have an experience they can share and how it was handled? Were you satisfied with the solution? I would prefer not to have Ford buy it back but I also don't want problems two years down the road.

Any feedback on how to proceed with the dealer & Ford?
When I first read your post, I thought this is probably some complaint over light rusting from exposure to the elements. After viewing your photos I’d agree with you and there’s no exaggeration happening here. That is totally unacceptable and it seriously looks as though the tuck was built and parked in a field for a long ass time or they used parts that sat in a field for a long ass time. Either way, that should have never reached a customer for sale and should have never left the plant much less passed the dealers PDI that YOU paid for. Give them a chance to fix it, replace it or do something but I’d try to keep the miles down as much as possible or not drive it at all if you can live with it until they correct the problem. I think I’d also be on the phone to an attorney to have a back-up plan. At the very least you should be able to get Ford to extend your warranty out much further than the standard one. Good luck and keep us updated.
 
About to take a 2023 delivery (ordered 11/25, built 2/7). How's the community feeling about this rust? The exhaust system looks fine, but I did snap some pics of of the diff, axles, etc. I'm feeling pretty good, but I also want the new truck that I've been waiting for.
 

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About to take a 2023 delivery (ordered 11/25, built 2/7). How's the community feeling about this rust? The exhaust system looks fine, but I did snap some pics of of the diff, axles, etc. I'm feeling pretty good, but I also want the new truck that I've been waiting for.
My understanding is this is the normal amount of rust that the dealers are seeing. The connection plate from the transfer case to the drive shaft looks to be the biggest concern. I would have them replace that as it looks to be near pitting. Also, be sure to check the front of the drive shaft under the front end.
 
See no rust on the axles to that sweet BRAVO stroller :- ) All kidding aside overall, not that bad, but agree with @Malachi about the possible pitting on the connection plate to the transfer case. If doesn't take much, to clean up, but for what we are paying for these trucks they should be done right. I would see it the dealer will replace the connection plate and undercoat the affected area at least. Doesn't hurt to ask!
 
Bought mine last week and have just as much rust as Malachi. Went to my dealership yesterday and they are going to make it right by cleaning it up and undercoating it for me tomorrow. I could tell they are also frustrated that Ford has put them in this position. Shame on Ford for doing this to the consumer and putting people in this position. Love my truck, but not happy that this even has to be discussed.
 
About to take a 2023 delivery (ordered 11/25, built 2/7). How's the community feeling about this rust? The exhaust system looks fine, but I did snap some pics of of the diff, axles, etc. I'm feeling pretty good, but I also want the new truck that I've been waiting for.

Mine looks a lot like yours. Most of the rust appears to be concentrated around the connection plate at the rear diff. The dealer I purchased from said it was nothing to worry about, but I'm not sure if that's true. I've since moved to another state and may have the local Ford dealer here take a look and give me feedback. If I do, I'll post an update.
 

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“Surface rust on carbon steel components of these vehicles is not out of the ordinary. It will not cause any warranty issues. PDI will not do anything to remove this rust.“
- Dealer

No luck on my end. I will do what @TremorLucky is doing and just bug the dealer any time it’s in for service. As long as any impacts from the rust are still covered under warranty, I’m not too worried about it. I imagine it would like this after a short while anyways. Not pressed on getting it to look pristine for a few months then looking like this anyways.

I’m using X-Plan, so I’m sure the dealer isn’t scrambling to “make the customer happy” as they’re not making much on the deal.
 
Took deliver last summer on a '22, and the two areas beyond surface rust-

20230308_130854.jpg

20230308_131009.jpg

Same response from dealer so far ("not a big deal").
 
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My axle isn't nearly that bad but the exhaust system from the cats to where it Y's together looking similar. I think they probably parked these things for a bit before they were transported, maybe in a parking lot they salted or something. Definitely looks pretty terrible.
 
My axle isn't nearly that bad but the exhaust system from the cats to where it Y's together looking similar. I think they probably parked these things for a bit before they were transported, maybe in a parking lot they salted or something. Definitely looks pretty terrible.
Many of those parts have no paint or a light dusting of paint, so they'll get surface rust quickly. I see this as simply an appearance issue. I've owned 50-60 year cars that all of those components are completely rusted over and still work fine. If the appearance is important, wire brush or wire wheel the heavy stuff off and apply a rust control primer and black paint. You can go a step further and coat with something like POR-15 available from Eastwood and you'll never see rust again.
As far as the exhaust goes, isn't that stainless?
 
not sure if there's some kind of undercoating that can be sprayed on or applied to prevent any further rust.
 
not sure if there's some kind of undercoating that can be sprayed on or applied to prevent any further rust.
Amsoil HD metal protector, it will darken the rust and will not get any worse. I did my truck almost 5 years ago when it was new and it still looks new today. I redo the wheel wells maybe once a year because I’m always spraying my truck off especially in the winter from road salt. I did the whole truck with like 2 cans.
 
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not sure if there's some kind of undercoating that can be sprayed on or applied to prevent any further rust.
 
About to take a 2023 delivery (ordered 11/25, built 2/7). How's the community feeling about this rust? The exhaust system looks fine, but I did snap some pics of of the diff, axles, etc. I'm feeling pretty good, but I also want the new truck that I've been waiting for.
This is how mine looked also but i told them i wanted it fixed so they did
 
Ya mine isnt much better. I also submitted a claim.

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Many of those parts have no paint or a light dusting of paint, so they'll get surface rust quickly. I see this as simply an appearance issue. I've owned 50-60 year cars that all of those components are completely rusted over and still work fine. If the appearance is important, wire brush or wire wheel the heavy stuff off and apply a rust control primer and black paint. You can go a step further and coat with something like POR-15 available from Eastwood and you'll never see rust again.
As far as the exhaust goes, isn't that stainless?
exhaust is stainless 409, which will develop rust on the outside. Which appears is what happened.
 
Many of those parts have no paint or a light dusting of paint, so they'll get surface rust quickly. I see this as simply an appearance issue. I've owned 50-60 year cars that all of those components are completely rusted over and still work fine. If the appearance is important, wire brush or wire wheel the heavy stuff off and apply a rust control primer and black paint. You can go a step further and coat with something like POR-15 available from Eastwood and you'll never see rust again.
As far as the exhaust goes, isn't that stainless?
At $70k+ nobody should have to lay under a new truck and paint anything to hide rust thats developed on something thats less than a month old. I agree its appearance, but again at $70k + it should appear good, not rusted.
 
At $70k+ nobody should have to lay under a new truck and paint anything to hide rust thats developed on something thats less than a month old. I agree its appearance, but again at $70k + it should appear good, not rusted.

I agree - it's an eyesore that should not be present on a new, highly-priced vehicle.
 
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