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

[Stampede.Offroad]

I agree if you have it in a garage and also pool chemicals like chlorine tabs or acid… eventually those items will rust and wreck everything metal…

That was my first thought too, chlorine. I've seen the results of a leaky bottle in a wash room next to a metal shop. Rust on everything in days.

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[lakesinai]

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.

OP, I've driven on the Beach since receiving my OBX in October 2021, from Florida to North Carolina. There's no rust, anywhere on my OBX. (Photo of under my seat.) Your car has all the signs I would expect from a hurricane flood damaged vehicle. Or submerged in the surf. With rust inside bracket joints like your last photo, its more than simply missing paint (some 2021 Broncos did have incomplete paint, but your non-MIC, December delivery Bronco is likely too late for that). Perhaps someone borrowed your car for a joy ride in the surf? Something doesn't add up here.

 

[fwade4]

OP, I've driven on the Beach since receiving my OBX in October 2021, from Florida to North Carolina. There's no rust, anywhere on my OBX. (Photo of under my seat.) Your car has all the signs I would expect from a hurricane flood damaged vehicle. Or submerged in the surf. With rust inside bracket joints like your last photo, its more than simply missing paint (some 2021 Broncos did have incomplete paint, but your non-MIC, December delivery Bronco is likely too late for that). Perhaps someone borrowed your car for a joy ride in the surf? Something doesn't add up here.

Unfortunately no, I am the only person who has driven the Bronco. Can 't even trust the wife

 

[Rocky Rocks]

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.

Same issue with the panel underneath the steering column. I removed it in tact, replaced it, the following week it was starting to rust as if contaminated by touching. I've always had the Midas touch but as of late....

 

[stickshifthappy]

Same issue with the panel underneath the steering column. I removed it in tact, replaced it, the following week it was starting to rust as if contaminated by touching. I've always had the Midas touch but as of late....

At this point the only logical answer is, you've got a zombie Bronco on yer hands.

 

[pandasloth]

Even with the doors off and top down ober multiple days, an ocean mist should not cause corrosion to happen so quickly.

But, perhaps something more nefarious like maybe a jealous and/or shitty person may have thrown ocean water into your interior? Any chance of that happening? Was the interior more wet than a morning dew at any point?

 

[Grumpy]

Wow, thread retitled, 10 pages of the same responses.

 

[Dorf2point0]

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.

I think the key is Virginia.. When I lived there the humidity was terrible in the summer.. Running the A/C just complicates the issue because when you open the doors to the humidity all that cold air in the car wants to condense the humid air. Coming in.. It may not be apparent but cold air drops under the seat.. Those under seat parts are chilled.. Now, open the door and the humidity flows in and immediately condenses on cold surface.. A simple trick is to let the Bronco run with the heat on directed to the floor.. Make sure there is nothing under the seats to allow maximum air flow.. it will partially dry the parts, warm up the parts, so when you open the door the surfaces don’t condense.. I would also check under your dash. The same problem might start there if it hasn’t already ..
Good luck in this journey..
Richard

 

[Sparkherd]

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.

I've had half my interior out, and haven't found any unpainted surfaces...this ain't right.
How long did it sit on Rust Mountain™?!?

 

[OX1]

I've had half my interior out, and haven't found any unpainted surfaces...this ain't right.
How long did it sit on Rust Mountain™?!?

That's what I'm wondering. How long did it sit with maybe a top missing, or a window open, before you got it. Even with that, that headrest "chrome" is brutal, not that far off of some pieces from my 40 year old rock crawler (like the sunvisor mounts on a 78/79), that did get completely submerged once.

 

[MannyG20]

The OP said he has left the top down several nights throughout the summer. Morning dew is the reason for the corrosion. Thats why is so widespread and even on the headrest mounts.

I don’t buy that. This is a vehicle that you are supposed to spray down to clean, remove the top and leave it off, drive thru standing water. There is something else going on.

 

[MEAT_GOD]

The heck? I've literally gotten my Bronco stuck in a sea bed at low tide and it hasn't rusted one bit, meanwhile you've got this. There's definitely more than what meets the eye.

 

[Rayder]

This is something beyond salt spray. The chrome is particularly telling, as is the pervasiveness of the corrosion. I would be willing to bet that at some point it was exposed to a gaseous oxidizing agent like chlorine, fluorine, bromine, hydrogen peroxide, etc. When and where is really the question.

 

[swooshdave]

The OP said he has left the top down several nights throughout the summer. Morning dew is the reason for the corrosion. Thats why is so widespread and even on the headrest mounts.

Not true.

OP was at the beach and left it wide open (no top, no doors) and ocean mist got inside. A lot.

Just dew won't do this.

 

[Emerald]

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.

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.

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