Rust is a common issue with Ford Rangers from 2012 to present. The problem is extremely widespread within the UK (and other countries) and varies from vehicle to vehicle. Some owners quoting, “The vehicles are being produced to an un-satisfactory quality due to insufficient underbody coating”.

Timeline of Events

A Ford internal repair instruction was leaked during 2020 dating from 22/01/2015, applicable to Ranger’s 2012 onwards. To view this document click here. (This is now outdated and not being used)

From 22/03/21 Ford started building / appointing 10 'Centre of Excellence' across the UK. For chassis rust, this is the only place your vehicle can go for official treatment from Ford. This treatment is free and a ‘gesture of goodwill’ from Ford.
New treatment (which may vary) involves stripping the vehicle down to the chassis, sand blasting, priming, 2K paint, Teroson coating, then vehicle rebuild. This process can take up to 9 weeks and a courtesy vehicle should be provided.
Before receiving treatment there is likely to be a considerable wait due to the number of vehicles being treated.
The current known Centre of Excellences are: Allied Ford Glasgow, Ford Dagenham, TrustFord Birmingham Erdington Transit Centre, TrustFord Gillingham Transit Centre, Broach Hill Driffield, Impact Repair Centre Redditch, Luton.

After repair completion you will receive a ‘post repair survey’ and a free service token that can be redeemed at your local dealership.
From 15/03/22 Ford are offering an alternative repair to eligible customers. This involves vehicle uplifting, full vehicle strip, chassis replacement (pre treated with wax oil), then rebuild. The chassis replacement process will require a ‘rebuild’ marker to be placed on the vehicle record with the DVLA, and the V5C document will be updated to include the statement “Rebuilt - assembled from parts some or all of which were not new”. The DVLA will automatically issue the customer a new V5C document upon treatment completion.
The current 2 official treatment options are: (A) Chassis treatment (B) Chassis replacement
Ford announced on 07/11/22 that the goodwill gesture treatment will be coming to an end on November 30th 2022

Vehicles are being repaired on behalf of Ford as a good will gesture, following an inspection, at which point a chosen repairer is nominated based on: the customer’s agreement to the proposed repair method, the nominated workshop availability and geographical location to the registered vehicle address. Some of these workshops may also be constrained by other workloads, so it wouldn’t be possible for customers to nominate their own chosen repairer for this reason. You are correct that any Ranger customers who are unhappy with the visible surface rust should continue to contact Ford’s Customer Relationship Centre - and we will happily investigate the issue. I must reiterate that extensive testing has been conducted since this issue was brought to our attention and it is not found to be a structural issue. However, we do understand that vehicle appearance is extremely important for many customers - a vehicle which is their pride and joy or even the front of their businesses - hence the efforts made thus far to resolve the issue.
- Ford of Britain

07/11/22
The Ford Ranger goodwill gesture will close on Wednesday 30th November, 2022. This was introduced in March 2021, determined by Ford to be the correct approach to address visual concerns regarding surface rust on some chassis of customer vehicles, limited to those first registered from 2015. All Rangers are built with a protective underbody electrodeposition coating (e-coat), which if damaged by the user or by external factors can cause surface rust to appear - often across welding joints. This does not affect the structural integrity of the chassis and is cosmetic in nature. This is not, or has ever been a structural or safety concern, or a warranty item.
Ford is now satisfied that the majority of customers expressing concern about the visual impact of this surface rust have either:
-Had their vehicles returned to them with any remedial work carried out
-Contacted the Customer Relationship Centre to arrange an inspection, or
-Are awaiting a date for any remedial work to be carried out

Customers who have not yet contacted the Customer Relationship Centre have until Wednesday 30th November 2022 to submit their request for an inspection to determine whether the vehicle is eligible for the goodwill programme*. Any submission after this date will not be eligible for assessment as part of this goodwill gesture.
*Subject to terms and conditions: Within three years of customer purchasing a Ford Ranger, first registered from 1st January 2015.

Since the goodwill programme was introduced, the majority of customers have shared that they are satisfied with the remedial work carried out, contributing towards Ford’s ongoing efforts to treat customers like family.
- Ford of Britain

ALL COMPLAINTS OR QUEIRIES NEED TO GO THROUGH: ukcvsc1@ford.com

When contacting the Commercial Vehicle & Fleet Service Centre, it’s important to include the following information to speed up the process: Full name, Full address, Contact number, Vehicle registration date, Vehicle registration / number plate, Images of your chassis.

For ease we have pre-written an email draft which you can copy from the comment section at the bottom of this page.

Other possible alternative avenues you could take are:

If your vehicle is on finance (such as Ford Credit) you could refuse the vehicle / request a refund on the grounds you were sold a faulty product. Your vehicle will need to be in stock condition upon return
If your vehicle is on finance (such as Ford Credit) you could complain to the Financial Ombudsman service. They will act as an impartial ‘middle man’ to help both parties come to a mutual agreement
You could complain to the The Motoring Ombudsman
You could complain to Trading Standards
You could open a court case
You could treat the vehicle yourself with a product such as Lanoguard or Dinitrol

For more info visit the Ford Ranger T6 Rusty Chassis group

Before Treatment

2019 Ranger (9,000 miles)

2019 Ranger

2012 Ranger

2016 Ranger (29,000 miles)

2018 (8,000 miles)

2015 Ranger (38,525 miles)

During Treatment

During Treatment (Dagenham plant)

Trucks awaiting finishing wax treatment

New chassis with improved finish

Example of what the rust looks like and the condition of most that are being replaced

All parts are listed on a wall with examples for the technicians to follow. When building the chassis, many parts are single use items; for example many high torque bolts that should not be re-used

Ford Ranger Rusty Chassis Issue

UPDATE

BELOW

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UPDATE BELOW 🛑

Rust is a common issue with Ford Rangers from 2012 to present. The problem is extremely widespread within the UK (and other countries) and varies from vehicle to vehicle. Some owners quoting, “The vehicles are being produced to an un-satisfactory quality due to insufficient underbody coating”.

Timeline of Events

ALL COMPLAINTS OR QUEIRIES NEED TO GO THROUGH: ukcvsc1@ford.com