Surface Rust Found on Frame (Front Jack Points)

[huey]

so I just stumbled across this thread - I have not read each post but it does seem this thread receives updates from the OP as well as other new posts with similar complaints
I will add my .02 as I have first hand knowledge of how these frames are built, shipped, and built into trucks

There are two identifiable types of "rust" in these pictures
1) in the weld seams. This is completely normal and unavoidable as the weld process generates pockets of silica islands. a normal part of welding. in fact those spots may not be rust at all as silica islands are brown . The paint used on the frame(known as ecoat) will not stick to silica. You would have to grind out(not sand) the entire pocket of silica for paint to adhere to it. this could potentially remove some of the weld you don't want to remove. Also The ecoat process is a very lengthy and way more durable process than even a properly applied POR15 product(POR15 is a fantastic product btw)
2) on the surface of the metal. This is likely due to material handling of the frame. This could happen in many locations, at the factory where he frame is produced, on the rail car when frame shipped from frame plant to Ford, or at Ford. Know this is just surface rust where tow motor forks have rubbed away a small portion of the ecoat. This is no different than if you drive down the road and get rock chips, or get the frame up against a rock offroad. You can touch up these areas if you wish, but this will be a never ending process and will not not impact the frame integrity one way or another.

Keep in mind all OEM's including Ford run vehicles thru durability testing including a salt spray test to validate the ability of the frame to hold up over time. in other words frames are going to get some rust on them.

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[BadlandsA51]

I had rust In the same area but worse. Wonder if it was from the train ride (tie downs?) as my dealer didn’t even seem to bother with PDI. Either way I lightly sanded and sprayed the whole undercarriage with PB Baster Surface Shield. It’s rated better than Fluid Film for longevity and you can buy it by the spray can at Home Depot.

Could be just from shipping from where the frame was built to the assembly plant, or handling in the assembly plant. Frames aren’t handled with kid gloves, they’re big, heavy, and awkward to handle.

 

[FORDGE37]

I know I'm late to this post, but I just purchased my 2025 Outer Banks in late April 2026. We have about 350 miles on it now. Just finished my complete detailing, ceramicoat on all finished paint (main body, door jams, under hood, etc).

Last night I cleaned/detailed/waxed the bottom of the truck... yes, frame and painted under body area. I'm a long time StreetRodder (1937 Dodge w/ a 351W SBF) with a bit of OCD, I want the bottom of this Bronco to last as long as the top... Garage kept, but midwest winters (e.g. salt, sand, coal, etc)... always "warm" pressure washed before nightly garage storage. I know my prep and ongoing cleaning routine will prevent rust, and I accept some rust. My 2008 Suburban w/ 283K miles has ZERO rust on the body, but I didn't wax/detail the frame and it has some rust...but overall a "top 2% condition" due to proper cosmetic (and mechanical) maintenance.

What is up with the driveshafts and front axle shaft rust??? So much from the factory/dealer. I'll investage some thin paint for them, something that won't impact balance. Consider the weight of spray can paint, and figure that a lot of it is propellant, I'll assume fractions of an ounce of paint. similary, consider the large amount of grease or crud on a lot of cars, there far more weight than paint would give, and the grease/crud isn't uniform like my paint will be.

Also, typical rust spots on front bottom of frame where lifts scratched the frame... @huey any suggestions on paint to match the ecoat? There are some weld/silica-island discolorations/oxidation, but I'll live with those and hope the ecoat doesn't "lift" next to the silica-island.

Thoughts on fun colors to paint driveshaft/axles? I'll probably go Rustoleum satin-black, but know that some fun stripes would be fun too! Not just for me, but for the folks I pass on the highway, and the maintenance guys at the Ford Service Departments.

 

[Ducati1098]

What is up with the driveshafts and front axle shaft rust???

It's just exposed metal, it isn't ever going to cause an issue.

 

[FORDGE37]

It's just exposed metal, it isn't ever going to cause an issue.

Yes, just surface rust and no mechanical/operational issues. But it looks like $*!t under my (wife's) prestine Bronco. Again, a bit OCD, and I like to keep my vehicles just as clean under as on the top... This Bronco is great, I can roll around under it on a mechanic's creeper... Now my 37Dodge, I can't even get a floor jack under it without parking on 2x6 wood blocks...

 

[broadicustomworks]

No recourse. Saw your FB post about it as well just now.
The only visual remedy you can do it to get the rust off and coat it with some paint.
We all have the same situation, just the way they did it, like Ducati said.

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