rochesteredge

Rust is age and exposure and not mileage. My previous F-150 pickup never showed this rust after 5 years! This is on upper edges where gravity takes water away. Not a sign of rust on the bottoms of the rear doors, nor the top or bottom edges of the front doors or the rear hatch. Modern Ecoat (electrodeposition primer) has excellent corrosion protection and unless perforated or never applied properly, withstands much harsher salt spray testing than 4 Michigan winters. It may not be a Ford problem exclusively, but when only certain panels show the problem its design or painting or assembly. I have been in the assembly plants and seen the Ecoat dip tanks the body goes through. Even rustproofing wont help if it cant get up into the seams from the inside because there is no room for it to be sprayed in.

It is not thread filings! Not when the paint is bubbling. It is also on the upper edge and gravity would take away the filings. This is rust coming from under the paint or on non-ecoated bare metal inside the door. The front hood edge looks the same and there are no thread filings there. I wish it was this. It will eventually perforate the surface but probably after warranty expires.

First my rear doors (both) were rusting on inside upper flange where outside and inside metal is folded together and welded. Now I find rust coming through on hood on the inside front edge of hood, again where inside and outside stampings are attached and welded. Not showing rust through outside so no Ford warranty. 2009 edge with 65K mostly highway miles here in Michigan. I tried twice to get Ford to warranty repair but they hid behind the "perforation" excuse/language. And of course they said, yes its rusting, but not enough to warranty. I even emailed a couple of Ford paint engineers but received no response. Ford's doing good and does not give a S**t about the customer. Just had to replace a rear wheel bearing as well. I guess I could excuse that with the mileage, but, would a Toyota have this problem at this mileage. Shame of it is I really like the Edge, styling, handling, space. Only way I can punish Ford is not to buy another one for awhile. So, Good by Ford, Mullaly and company you are not there yet. I worked for an OEM paint supplier, and this rusting should have been solved with Ecoat, but design, painting process and assembly could still cause it. Good bye Ford, Will try GM or Chrysler one more time. Then its on to the foreign guys, and that is not what I want to do.

I have a 2009 Edge with rust blistering on upper rear inside seam of "both" rear doors. Contacted Ford, sent to dealer. Dealer said it would not be covered because it is not a perforation, but agreed to send in pictures and paperwork anyway. I had to call back to find out decision was no coverage. I called Ford service 800 number and talked to a supervisor, Cindy. She acknowledged I had a problem, but said it was not covered because of perforation. I said thats like being diagnosed with Cancer Stage 1, and having the Doctor tell you he cant work on it until it reaches Stage 4. There is not another spot of rust on the car. Its not one rear door but both, and both in the same place! This has to be an assembly or painting problem (ecoat primer should have gotten into these spots on the car doors). I told Cindy that I cant see buying another Ford (I also have owned an F-150) if this quality issue is not resolved. She quickly said there are many choices out there and Ford does not care. I have one more year on the "perforation warranty" and if it does not perforate my tough luck. It will eventually rust through on the inside of the door and the outside. I have basically liked my Edge (original Hankook tires wore out at 30k miles and I have rotor warpage at 60K miles), and had even thought of buying a new Edge or Explorer. Not likely now. They used to build cars like this, but with 2 side galvanized and ecoat primer it should be a thing of the past. Jim Farley may want everyone to know of Fords improved quality, but this is not it.