Terrible Rust Throughout My Bronco Interior - How Did It Happen?

[Archedamian]

Fertilizer in your garage?

This looks like something sulfur gas might do also.

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[fwade4]

I am the first owner of the vehicle after waiting almost a year and a half for my reservation number to get called. It was shipped directly from the factory via freight and I received it a couple weeks after the build was complete. I took possession on December 4, 2021 and it is a 2021 model year. I live in Virginia and vacation in Delaware. I never leave the top down in Virginia over night as my previous car was stolen. However, for our three week trip to Delaware last July, I left the top off during the day (and doors) and also several nights. We are about 3 blocks from the beach and there were a few days of decent seaspray but that is the only time this could have occurred. I never have moisture buildup on the interior windows and really have been blown away by how air tight the Bronco is even as a soft top. I did wipe the Bronco down after we left the beach but I guess I didn't get under the seats and would never have guessed to wipe down the soft top or try to access the behind the steering column cover.

 

[SuperFord]

Is anyone else experiencing the INSIDE of their Bronco rusting? Basically, any unpainted surface in my Bronco is covered in rust. I have never left the roof off in the rain or gone into deep water. I tried to have it covered by Ford but they rejected it under the corrosion warranty. If this isn't corrosion, I do not understand what corrosion is.

as others have said, the surface rust on the unpainted metal under the dash and seats is unfortunately considered normal, although I agree it is a little surprising to see it to that degree on a vehicle that is only a year or so old. and honestly, I would suspect exposure to moisture somewhere along the line.

the headrest chrome rusting is NOT normal.

and FWIW, the "corrosion" warranty only covers sheetmetal body panel PERFORATION, so unless that stuff rusts literal holes in the metal it is not covered there.

 

[userdude]

Ziebart it baby!

I am in no way affiliated with this company, just remember the commercials years ago.

 

[swooshdave]

I am the first owner of the vehicle after waiting almost a year and a half for my reservation number to get called. It was shipped directly from the factory via freight and I received it a couple weeks after the build was complete. I took possession on December 4, 2021 and it is a 2021 model year. I live in Virginia and vacation in Delaware. I never leave the top down in Virginia over night as my previous car was stolen. However, for our three week trip to Delaware last July, I left the top off during the day (and doors) and also several nights. We are about 3 blocks from the beach and there were a few days of decent seaspray but that is the only time this could have occurred. I never have moisture buildup on the interior windows and really have been blown away by how air tight the Bronco is even as a soft top. I did wipe the Bronco down after we left the beach but I guess I didn't get under the seats and would never have guessed to wipe down the soft top or try to access the behind the steering column cover.

Ah, I'm afraid it's Ocean 1 and Bronco 0. Saltwater spray on bare metal is going to corrode. Saltwater spray on chrome if not cleaned will rust at some point.

I hate to think what the underside of the Bronco looks like.

 

[ohp138]

Ice/Mud Mountain unit sitting outside for XX months?

Same question I was going to ask.

 

[Grumpy]

I've seen many convertible vehicles in my time new and not so old have surface rust on the seats under-framing, that is quit common. The headrest posts are chrome coated, and that is from moisture. You said you haven't done anything to promote this. Yes you have. You have left the top down overnight, many of nights in summer. Moisture in the air not rain caused this. Dew is moisture, midnight air is moist and the big word HUMIDITY. That is why you see this is all the hidden areas. The headrest posts can be wiped away for the most part.

Edit: the seat frames will not get any worse. Its just surface rust. You can take your hand and it will rub off on it. They will not rust excessively like a older vehicles fenders.

 

[UM_Ftown]

The headrest post is the only thing that I can say is not normal, the other component are all normal.

Came here to say this, I think it all looks normal until I saw the headrest.

 

[BlueBronco]

OP, try hanging one of these in your sealed up Bronco and see what you get after a couple of days.

As other have pointed out the headrest stem rust is very unusual and most likely the result of saltwater or some other contaminate

 

[Grumpy]

OP, try hanging one of these in your sealed up Bronco and see what you get after a couple of days.

As other have pointed out the headrest stem rust is very unusual and most likely the result of saltwater or some other contaminate

Maybe more like a week. Good idea!!

 

[Area51BS]

Under dash untreated metal I have seen a lot in my days of car audio. Head rest would be an issue. Will be lubing soft top joints.
For what’s it’s worth I live within ear shot of ocean and hearing boats in the intracoastal river where I am. Have none of that rust. It does go in the garage as of last week.

 

[Dmorty217]

Agree that under seat/dash normal but excessive, IMO. Headrest stems, nope. Something wrong there and would suggest some type of environmental fallout if it rubs off, if not, warrantable defect.

Did the vehicle sit at the plant for an extended time? Was it shipped by rail? Ever get caught in the rain with top down? Any fabric protection applied?

Mine was shipped by rail, been in the rain with the top down and I live relatively close to the ocean (6 miles) and I have none of what he has going on. The under side of mine looks brand new for the most part, as in no rust and I also went through hurricane Ian and drove through water for a solid week on the streets 12-30” deep

 

[Techun]

I've seen many convertible vehicles in my time new and not so old have surface rust on the seats under-framing, that is quit common. The headrest posts are chrome coated, and that is from moisture. You said you haven't done anything to promote this. Yes you have. You have left the top down overnight, many of nights in summer. Moisture in the air not rain caused this. Dew is moisture, midnight air is moist and the big word HUMIDITY. That is why you see this is all the hidden areas. The headrest posts can be wiped away for the most part.

Edit: the seat frames will not get any worse. Its just surface rust. You can take your hand and it will rub off on it. They will not rust excessively like a older vehicles fenders.

There's going to be that humidity in a car whether the top is down or up. There are vents, a car isn't a sealed system.

 

[mC.242]

Very strange. I live in San Diego and have had my Bronco since Aug 2021 and don’t see any of this. The only rust I’ve seen is on some exposed iron stuff in the undercarriage - nothing unusual.

 

[Dorf2point0]

I was at the beach for three weeks this past Summer and the second day there I noticed rust dripping from the soft top joints into the trunk. I didn't notice the rest of this until last month. I don't live near the ocean and do not have a pool. The pictures are - under both front seats, behind the steering column, the rear headrests and the soft top.

Ouch… And Ford won’t address it…

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