I recently had a small prang in my 2015 Territory which resulted in the bumper being replaced. The panel beater alerted me to some rust in the boot! He said he'd seen quite a few with the same issue - it's down to manufacturing process. Do you know how widespread this is?
It’s relatively widespread, Steve. In fact, it was enough of a problem for a while there that Ford was actually repairing some cars that were out of warranty. So that would be the first step: Tackle your local Ford dealer and ask the tough questions. A vehicle made in 2015 is too young to be rusty through bad design, but bear in mind that the dealer may not want to know and playing hardball on your part could result in legal costs if you follow it right through. And there’s no guarantee you’d win anyway.
There are shortcuts to rust repairs, but they all guarantee that the problem will recur. Fixing rust permanently requires removing all the affected metal, welding in new metal and rust-proofing the end result before repainting.
Somehow, moisture was able to enter the skin of the Territory’s tailgate and sit there and, naturally, rust was the end result. The area at the rear of the car around the tail-lights is also susceptible to corrosion. It’s interesting that the Territory had a storage space beneath the boot floor that was designed to accommodate wet bathers and wetsuits after a trip to the beach. Could this be the clue?