Ford Excursion :: Rusting Roof - Solution?


Oct 13, 2015

Looking for any creative solution for roof rusting that does not involve a major body shop repair and paint job. I was wondering if it could be chemically neutralized and then covered (sealed) with something like Line X?

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Santa Fe (CM - 2007-12) :: Front Edge Of Roof Panel Is Severely Rusting From Corner

So my vehicle is 6 years old and the front edge of the roof panel is severely rusting from corner to corner. Warranty originally tried to pass it off as stone chips (lol) before I got an independent surveyor to inspect. He said there's no doubt it's a manufacturing fault and is rotting from the inside out. I went back to Hyundai with this appraisal letter to which they replied 'your anti perforation warranty only covers from the windows down so the roof isn't covered.

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Ford Excursion :: 2003 7.3L - Oil Pan Rusting

While getting my oill changed, the pit guy reported my oil pan was rusting. I happened to be at the non local friendly FORD Dealer and mentioned it to the Service Manger who told me it was "the lousy steel FORD uses and your Differential covers are probably rusting out, too". And they are - from the inside out.

Seems strange to me oil bathed steel could rust, but the Dealer said the engine had to come out to replace the oil pan with an OEM. He would install a SS aftermarket, but he wouldn't warrent the pan.

So, where can I get a Stainless Oil Pan and Diff covers for a 2003 7.3L X?

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Ford Excursion :: Hitch Is Rusting / Removal?

My hitch is rusting so bad that I can pull it off in pieces. Surprisingly it seems to be the only major rust on my EX. I crawled under it the other day to check out how it is removed and I only saw half of 4 bolts. Those bolts look like they are under the fuel tank and I can't get my socket onto them.

My question is, do I need to drop the fuel tank to remove the hitch, and also is there anything else I should do while the fuel tank is down.(Besides replacing the hitch with a new one.)

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Ford Excursion :: 2005 - Rusting At Bottom Of All Door Panels?

I just noticed my excursion is rusting at the bottom of all 4 door panels With the rubber seals you wouldn't notice it unless you look for it. I was thinking of using pro-15 metal prep before the por-15, how did it work?

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Ford Excursion :: Roof Vents Falling Out?

How to keep roof vents from falling out? I had one that was falling out in 3rd row for quite a while which did not bother me to much but today had 1 on passenger 2rd fall & hit my mother. So my question is what can I do to keep them in? It's like PO wrecked all of them he was very messing owner I'm still finding pop in spots on the headliner.

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Ford Excursion :: Removing Of Roof Rack Rails?

Just got a mild lift done on my Ex and still wanting to park it in the garage.

If I remove the useless rails and cross bars that looks like it's still a possibility.

What to fill the holes with? Just torx screws? Anything else I need to do to prevent water leakage?

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Ford Excursion :: 2004 - Roof Paint Cracking And Lifting

I happened to look at the top of my 04 Excursion yesterday and found the paint cracking and lifting off the roof. So the first thing I did was to come look here and see if it was a common issue. I searched and found a couple threads about this issue from 2 and 4 years ago.

Apparently, the paint was applied too thick and that is why it cracks, lifts and breaks off. Some said they went to ford and ford has offered some type of discount on the repair.

But, that was years ago and I'm not sure if I think that ford is liable to fix this on an 8 year old vehicle.

I uploaded a couple pictures of the sots : Roof Paint Cracking - Picture

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Ford Excursion :: Building A Custom Roof Rack - Where To Mount It

I've seen a lot of off road racks mounted into rain gutters or the side of jeeps and whatnot, but can I just use the factory rails? Which way is better? The idea would be to remove the factory cross bars, and saddle up the custom rack in the rails that came with the vehicle.

Also, as far as weight is concerned the rack is going to be about 112" x 52" with a custom light bar in the front. The rack itself is going to weigh about 120-160 lbs. 1" square aluminum tubing., with 1 and 1/4 inch base, about 16-18" tall in the back, 10" in the front

I would like to be able to use a ladder and get up on it myself (200lbs), but I have a feeling this might be too much weight. me+sparetire+rack = fail?????

I know the rack itself can handle it I can jump up and down on it on the floor, but x roof is going to hold up or buckle?

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Ford Excursion :: Roof Leak / Water Coming From Overhead Compartment

Iv got a 00' Ex with water coming from the overhead compartment. The wires for the fuel mileage reader were eaten by a dog some time ago and the only electrical that look like are up there will be the controls for the rear A/C and heat. Any culprits for this type of leak? Iv done some searches, read through a few threads and haven't found anything with the same issue as mine. I will pull down the overhead compartment this week if i have time to check it but hopefully the rain stops soon. Ill try and get some pics after work today.

Edit: The water is dripping from that compartment right between where the face of the fuel mileage reader and base of the compartment go together if that makes any sense. But its just enough water to feel up my cup holder to about 1/5 full so not much but im not sure how long its been raining. Also no water is dripping/running down windshield.

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Ford Excursion :: Headliner Vent Repair - Where The Roof Vents And Dome Lights Go

How to repair where the roof vents and dome lights go? The headliner is in great shape, but a few of the vents have been pulled out and I would like to fix them.

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Nissan - Altima :: Windshield Washer Solution Not Spraying

I filled my washer tank full, when tried to spray, only the wiper moved but the solution never came.In the evening, i cleaned the spouts, with a tiny pin hoping that it will clear the dirt out, tried, didn't work either. Opened the hood, and saw the tank empty to my embarrassment. Is the pump broken, hose broken , what to look for and where and how to fix ?

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Buick - Regal :: 1995 - Turn Signal Lights Not Working - Solution?

Turn signal lights not working on a 1995 Buick Regal. I have replaced fuse & flasher but still didn't solve problem.

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Gen 2 Prius (Audio/Electronics) :: Static Noise By Mp3 Player While Plugged Into 12V Outlet - Solution?

Whenever I am listening to an audio device, like a phone or MP3 player, via the AUX connection, and I plug the device into a 12v outlet to charge, I get a loud buzzing noise. It matches the ICE in frequency, for example when I accelerate the static noise "ticks" increase in frequency, like it's picking up the engine cylinders firing. When the ICE shuts off, the static persists but it's not as loud.

I've used many different devices and both the console and dash 12v outlets with the same result.
I've tried many different car chargers- high quality, low quality, and even an Energizer battery charger with a USB port, but the noise always comes through.

Is there a solution for this? Or perhaps is there some "power cleaner" accessory I can purchase that isolates this noise from the outlet?

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Ford F-150 (2009-2014) :: 2012 - Rusting Out From Underneath

We just sold our 04 Supercrew that was rusting out from underneath itself. I was unsure of what to get next until I drove this 2012 F140 XLT supercrew with the ecoboost. It is in fantastic shape and drive great. It does have 90k on its odometer and I wasn't sure if that should be of any real concern.

It was a one owner trade in and you would never tell the mileage by looking at it. I averaged 5k miles per year for the 5 years I owned my 04 so I don't drive real far. I also tow a 20' ultra lite camper which may get upgraded to a 24' ultra lite in a few years.

I just didn't know if I should be concerned about the high mileage with my driving habits and not driving very much. Do these motors have any maintenance issues? Everything I've read seems to be good....

This story really piqued my interest : [URL] ......

2012 F150 XLT Ecoboost with 90k.....

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Ford F-150 (2009-2014) :: 2010 - Cab Corners Rusting From Inside Out

My 2010 F150 super crew cab is rusting from the inside out on both cab corners. I purchased my truck about 3 years ago with 75,000 miles on it. After about 3 months I noticed the 3rd brake light was leaking. I went to the dealer but they wouldn't warranty it due to the mileage. They did acknowledge that there was a problem with the 3rd brake lamp leaking and was willing to sell me new parts. So I repaired that ASAP. I don't how long is was leaking prior to that. Fast forward a couple years later the corners are starting to bubble. I am assuming this what caused the cab corners to rust.

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Ford F-150 (2009-2014) :: 2012 - Rear Bumper Is Rusting

My rear bumper is rusting pretty bad. I have polished several times, and it comes back worse every time. Its less than 2 years old and I have mud flaps. I brought it to the dealer today, and the writer was trying to pass it off as normal.

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Ford F-150 (2009-2014) :: 2011 5.0L - Exhaust Manifold Rusting Away

I was checking the oil in my truck yesterday. I noticed the passenger side exhaust manifold was flaking rust. I mean flaking bad, big chunks coming off. Even the heat shield was rusted bad enough that it is barely holding on. Looks like in a couple years will need replaced. I have never seen this on my other Fords.

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Ford F-150 (2004-2008) :: 2007 - Brake Booster Is Rusting All Over

Have a rusty brake booster? My truck is an 07' with 55k. Brakes work great, but the booster is rusting all over. Should I replace? The lower steering shaft doesn't look so great either.... I'm trying to attach a picture, but I'm having some issues.

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Ford 7.3L Power Stroke (1999-2003) :: Bed Rails Rusting Out

After returning home from our trip last week I was giving the truck a once-over and trying to figure out why I had less clearance with the cab lights and the camper. Well a quick look down under revealed the culprit, the cross rail closest to the front is gone where it comes in contact with the frame. The inside of the bed would flex when I walked on it , in turn most every time I would hit a bump or transition in the road the camper would hit the cab lights. The rest of the bed is in real good shape, those rails are almost shot. Dually beds aren't cheap and getting someone to weld in new rails probably won't be either. We have decided to keep it at least one more year, I may attempt it on my own, get my brother -in-law to weld in the rails..

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Ford Aerostar :: 1995 - Passenger Side Rear Plug Rusting

I recently changed the plugs on my 95 Aerostar 4.0L. I noticed the last service person did not replace with proper plugs. The van was missing occasionally.

The passenger side rear plug was rusty. I noticed a small loss of anti-freeze during the past year also. Could this be a lower intake gasket? Have not noticed any anti-freeze in the oil nor any exterior engine leaks.

I recently drove it for 150 miles. Sometimes after start it would miss, other times not. Looking for the type of diagnostic to be done.

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