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Ford Falcon 2001: Rust

I READ with interest readers' reports of rust on their Fords Carsguide January 11). I bought a new AU II Falcon Tradesman cab-chassis in May 2001 and rust started to appear on the seams on the back wall of the cabin in 2003. I showed it to my dealer and they arranged it to have it repaired. They said it was a manufacturing problem, and the repairer showed me two other Fords with rust. He said it was a common problem in Fords. In late 2005 rust started to reappear. When I asked about this, the repairer told me Ford would not pay to do a proper job, only a patch-up. This time more rust was found in the engine bay, and it was more extensive. Ford refused my request to have it repaired, and wouldn't provide an explanation when asked why the vehicle should rust so early in its life. I was told, however, that it wasn't a manufacturing problem. The repairer said Ford did not paint its cars properly to save costs and showed me three Territories with rust in their engine bays. In the end I had the rust repaired and paid for it myself.

I RECALL test-driving an XR6 cab-chassis last year and being horrified by the rust I found on the chassis under the tray. It was probably never going to be a problem, but it sure looked ugly -- and this was a new car, supplied by Ford. There are so many reports of rust in Falcons and Territories that you'd have to think there is a production problem, or perhaps Ford is cutting corners with the painting and rustproofing to save money.

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