I have an FG 1 tonner with some rust problems which the dealership servicing the car say they can't understand and don't seem to be able to fix. Maybe someone here can help.
I bought the car new May 2009 but is is a 2008 build. It has a factory tray and genuine towbar. Aside from that it is a standard, boring 1 tonner with automatic with which I am very happy aside from this problem.
The rust started to appear in the tray hinges around the lower bolts. It is kind of weird but every lower bolt in every hinge started to develop a rust halo a couple of mm wide. All of the upper bolts are fine.
The rust also started to appear around some of the smaller bolts in the tray surrounds. Problem was pointed out to dealership at service but they had to get authority from Ford to repair. After 2 months without response, someone finally chased it up and it was decided to replace the hinges and bolts.
In the meantime, the rust halos have grown - now bigger than the size of the bolt head; and the rear wheel studs (both sides) are corroding badly (but not the front); and the various bolts connecting the towbar to the car are also corroding badly; and some bolts in the rear suspension (not the front) are also corroded; and the edges of all of the galvanised steel in mudguards and brackets attached to the tray are corroding and (most worryingly) the seams in the cab metalwork are starting to rust.
The dealership says it has seen nothing like it and does not appear to be getting any factory support to resolve.
To me it seems to be an electrolysis problem and I am concerned that the delays are just making things worse. By way of background the vehicle is used in Canberra and rural NSW well away from the ocean.
Does anyone here have any ideas? Are there other areas I should be checking?