Unfortunately, our new 2011 Mustang came from the factory with some rust already spreading on the inside lip of the trunk lid. The car was just built on 1/7/2011 and I noticed it later the same day we took delivery. I couldn't believe our new pony was already rusting!

I took it back to the dealership where we bought it and their body shop took some pictures, so they could get Ford's approval to repair it under warranty. They got the approval and I will be taking it in tomorrow for the repair. They are giving me a loaner car and it should be ready for pickup the next day. I just feel Ford should have better quality control, so they could avoid producing cars with rust.

Below are some photos.

 

that sucks, at least they are fixing it..

 

Get under the car and look at the axles and rear-end housing if you really want to see some rust on your car. I'm glad they're taking care of it for you.

 

Yeah, I currently own 3 S197, so I'm used to the rusty rear axles, and even the corrosion on the aluminum hoods, just not elsewhere that's painted and brand new.

 

Holy crap!!! Now i need to check mine but its dark, wind blowing 40 m.p.h. and going to rain

 

For those out of warranty, there is a product called POR 15 which may help you. You remove the rust, apply the POR 15 (which goes on black), and then paint with your touch up paint. Since most of the problems are under the hood or now the trunk lid, it would be hardly noticable. This product stops future rust at the site.

Here is link to POR 15 site: http://www.por15.com/

 

+1
Usually you can just scrape off any loose rust. sand it smooth, then apply the POR15 to seal it.
Even if it is a little rusty still the POR15 will neutralize the rust and seal it.
I believe there is also a silver color POR15.
Oh and absolutely use gloves, it will seal your hands and paint them semi-permanently too.

 

Ohh my! That is bad (especially seeing it on a grabber blue!). Hope they get it fixed for you. Wonder how they let that happen...the car is only 2 months old!

 

Yeah, I noticed rust on rear axle and front end where I had scraped frame against raised manhole cover (and dented engine's aluminum oil pan, no leaks or other damage visible) and at various other points on frame, brackets, etc. when Mustang was on lift for routine service.

Plan is to address these points with Rustoleum rust converter, rusty metal primer and black topcoat next time I have the car up in the air.

It's just me (being underwhelmed by local dealership) but for a small bit of rust like on the inside of a trunk lid, I would lightly grind the problem area to bare metal with a burr rasp on a Dreml tool, then use a small paint brush to apply primer and color-matched top coat. In cases where folks had entire panels replaced with new, I've noticed mismatched colors. Also, you might have to wait MONTHS for a newly-painted part.

Friend of mine had a rear door panel replaced on his Pontiac G-8GT because there were painting imperfections that only he noticed, could have been sanded, compounded and buffed out (which I offered to do). Instead, he took it to the dealership where he had to wait three weeks (they did give him a loaner) to have the panel repaired or replaced, don't know which.
Not only did the color not match, the replacement panel had really bad orange peel and the door did not fit right.

He wound up going to a local body shop to have the job corrected, paid for it out of his own pocket. Car looks good now. The G-8 is a pretty neat car, very comfy, goes like jet stink and deports itself well on back roads. I think they're still making it in Oz, though not under the Pontiac name.

JMHO, unless it's a high-dollar replacement item, I don't trust dealerships to repair or replace even oil and filter. Find a local shop where they let you hang out and watch work being done.

 

I took it in for repair last week and they seemed to do good job, as it's unnoticeable now. Actually, the car wasn't even a month old. It was built on 1/7 and we took delivery on 1/23, and I noticed the rust that evening when I was installing the pedestal spoiler.

 

The corrosion repair isn't 3/36 it should be 5/100,000. Have to check for sure

 

Surface rust/corrosion is only covered by the 3/36. Otherwise, the rust/corrosion must be so bad that there is perforation, to be covered beyond the 3/36.

 

I noticed this last fall when I was cleaning mine up for storage. Exact same spot, the only difference is that it was just paint bubbling and no actual rust showing.

 

Took some photos of said defects.

 

Hi, Thanks for the photos. I'm not positive that the spot fixed on our pony was rust, because it looked more gray-colored. It could be the same imperfection on yours, just not as large. Regardless, IMO you should have them fix your car's imperfection under warranty, so that there's no concern about it spreading in the future.

 

Update:

Ford took my car in last Friday and had the paint defect fixed free of charge. Still not sure if it was just glue that was pressed out when they assembled the trunk, or rust. They didn't say when I picked it up..

 

I checked mine today and it looks just like yours.

 

This is unbelievable, the same thing is still happening with the 2011s. This has been documented since at least 2000, multiple models of cars and trucks, multiple law suits filed, yet they still continue to do it and they still continue to refuse to repair any of them past the 3yr/36K warranty. And they know darn well it doesn't surface in most cases until the warranty is out.

My hood is now garbage, the paint is bubbling and peeling off around the entire perimeter and is now on the top side. I am about to have to 1) spend $650 to have it stripped and repainted, or 2) spend $1277 on a new hood. On a 3.5 year old car with 44K miles on it. And that's just a-okay with ford.

There is no tsb on the 08's yet. When I asked why they said probably because the problem hasn't shown up enough yet. Right on, because it won't until the warranty is out. Corporate pigs.

 

This defect on the 2011s is not the same as the corrosion happening with the aluminum hoods on earlier S197s. This defect is on the inside of the trunk lid made of steel. I too have a 2006 S197 with corrosion on its hood. It was fixed once under warranty, but came back in other areas. It's pretty sad. Fortunately, the hood on my 2008 Shelby GT hasn't shown any corrosion yet. However, the SGT is a garage queen, so that probably helps.

 

My 2010 also has multiple defects on the trunk lid seem just like those pictures.