Rusty doors

Kamuelaflyer

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I'm wondering if this might actually be part of the issue. Maybe it has something to do with being transported across the ocean? Something something salty sea water
Most cars are not exposed to the elements when carried on a ship. The closest approximation for shipping the MME is to Hawaii, where they travel from San Diego to Honolulu and then to the other islands. The environment here is far different though. Very humid and warm (mostly).
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Front fenders and hood are made of Aluminium. The trunk door is plastic. The rest is steel.
 

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Hi there! Greetings from Germany.

Just registered here to cross check if people are having the same issues as we have over here.

I recently discoverd what looked like rust unter the paint on 3 of my Mach-E Doors.

The dealer checked it and now gets into contact with Ford to see what to do.

I asked others in a German Mach-E forum to see if they have seen that also on their cars. So far we have 4 with simmilar rust issues at the doors and 5 do not.

Anyone over here already has seen this? So far I didn't read much about rust issues with this car. Only some brake rotor rust that I would consider normal for EVs.

I wouldn't have wondered seeing such things after 5 years or so, as there isn't much rust prevention done from the factory. But the cars are all around a year old only. If people think the battery is the first thing to die, I now would be more worried about the chassis.

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It does look as though there's no sealant between the outer lip of the door where it folds over on to the inner skin. I noticed that on mine but no rust (yet). I do give it a heavy dose of ceramic sealant on that area when I wash mine. I suppose in theory that water can collect over time and find it's way into any gaps? ?
 


new to mach-e

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must be a ford thing: both our 2011 ford explorer and 2017 explorer suffer from rust on that lower edge seam. I made a point to regularly rinse out that area especially during the winter months with all the salt here in Michigan
 

Logal727

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Isn’t this part of a lifetime warranty?
 

hybrid2bev

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Isn’t this part of a lifetime warranty?
Rust damage resulting in perforation (holes) in body sheet metal panels is covered for: 5 years/unlimited miles. I don't think rusting out from the bottom is covered, especially if there are "extreme environmental conditions".

Corrosion damage is covered for 5yr/unlimited miles with NO requirement for perforation only for aluminum panels.
 

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I have the same issue on one door, the other 3 are fine. I’d say it’s likely a poor paint prep issue.
 

Guss-E 2021

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New England/NH owner. Have not really entered into true winter conditions with the car. Plenty of rain though. My car was built some time in April 2022. 8,156 on the odometer. No apparent issues at least on the driver's side. I should also mention I have dealer applied ceramic coating inside and out.

Ford Mustang Mach-E Rusty doors 20221031_134148
Ford Mustang Mach-E Rusty doors 20221031_134136
 

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To me, it's clear that the bare steel started to rust/corrode before it was painted. It happens. Should be covered under warranty.
 

DennisD

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To me, it's clear that the bare steel started to rust/corrode before it was painted. It happens. Should be covered under warranty.
Even though "it happens", I am quite nervous of the preparation of the rest of the car if this would be the case. A factory is a controlled situation that absolutely should not have this issue this soon. I have had close to a hundred cars in my lifetime and I have never seen rust this soon to someone's or my car.

Something had to have happened either in the shipping or the factory if multiple vehicles are showing this "rust". Now if someone were posting this with a car that is 5 years + with surface rust, I would understand this is possible for normal wear and tear.

Having issues with this on cars 2 years or under is not acceptable and even if the warranty covers this, this does not bode well for the car or it's value. If word gets out that this is a problem along with the electrical issues, we won't be able to give these away in a couple of years.
 

Pioneer74

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Hi there! Greetings from Germany.

Just registered here to cross check if people are having the same issues as we have over here.

I recently discoverd what looked like rust unter the paint on 3 of my Mach-E Doors.

The dealer checked it and now gets into contact with Ford to see what to do.

I asked others in a German Mach-E forum to see if they have seen that also on their cars. So far we have 4 with simmilar rust issues at the doors and 5 do not.

Anyone over here already has seen this? So far I didn't read much about rust issues with this car. Only some brake rotor rust that I would consider normal for EVs.

I wouldn't have wondered seeing such things after 5 years or so, as there isn't much rust prevention done from the factory. But the cars are all around a year old only. If people think the battery is the first thing to die, I now would be more worried about the chassis.

20221025_180157.jpg


20221025_180059.jpg


20221025_180038.jpg


20221025_180025.jpg
I can see the rust through the drain holes, but as a person that sees F150 truck doors every day, that might not be rust under the paint.

Between the inner and outer door surface, there is a bead of adhesive applied before they are crimped together. Sometimes the adhesive, if not applied in the correct spot, will squeeze out of the contract area.

Sometimes, after the vehicle is dipped in the prep tanks for undercoating, the liquid doesn't fully drain out of the bottom of the doors. After they are painted and put through the curing oven, the liquid will "boil out" and take the adhesive with it. To me, that is what I see here.

Now, over time, if there are any cavities in the seam on the bottom of the door because of the void left by the adhesive boiling out, you could have rust develop. I would definitely have it looked at.

At the very least I would spray some Fluid Film through the drain holes and try to saturate the whole bottom seam.
 
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LF-X

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Let's see what Ford suggests to do.

I'll spary some sort of sealing in the drain holes anyway when I get it back after repair.
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