I have a 16 Fist with 41000 km. Bought new. I am from Calgary Alberta Canada. About a 2 weeks ago (March 1) my wife noticed rusting on the hatch. I rubbed off some rust and the seam sealant broke off. I was wondering if it was my fault because I pretty much wash my car about once every 2 weeks in winter to take the salt away. But I am glad it wasn't because of my doing and it a ford defect.
Went to the dealer to complain (March 5) at 2:00 pm. Saw the auto body assistant manager and she took pictures of it and said tomorrow she will talk to her manager and sent it to ford. I mentioned why is it rusting after 3 years of ownership and that I have been washing the car about once every 3 weeks (But really did not want to tell them I have been washing it more often). Furthermore, explaining what was mentioned by other members here that rust should not be forming that quickly.
Next day, the auto body manager called over the phone and told me ford is not going to cover it because it is not corroding through the metal (as mention by members). They quoted me $1300 CAD to repaint and disassemble/reassemble the hatch.
I called ford service via the website on March 6. Lets just say it was a waste of 20 minutes. Pretty much repeated the same thing and was not helpful. No empathy at all.
The next day (March 7), I wanted to test my luck again, called the dealership to talk to the auto body manager and said I am coming down to see you. My reasoning for this, is that the manager himself did not see the rusting himself.
Spoke with him and he said its not as bad as the picture and it has not "corroded" through the metal. Because I was still under warranty for 6 months, he suggested I poke a hole in the same area of the panel every day to create a rust hole......
I mentioned to him that it is not my fault that this happened and that it was a defect in the paint. At that moment the auto body manager suggested a "TAPE TEST" to see if paint would peel off after taping it on to the panel. (He was using Scotchblue painters tape).
To our surprise it peeled off area of the tape which was a lot.
Next day (March 8), got a voicemail from him and he said that the
ford will cover it under warranty for paint chipping that caused oxidation of the panel.
From talking to him today to make my appointment (March 11), he said the the hatch needs to be sanded down and the whole hatch needs to be repainted. My appointment is set for March 25 and will take 3 to 4 days to get done.
What I learned from this experience is that you need to be persistent and keep complaining. Also you may need a ford employee like this manager (Nick) as he himself was a car guy and in his youth (maybe late 20s, early 30s).... in my opinion this guy was more helpful than everyone that work at the dealership (Marlborough Ford)... We need people like him.
Here are some pictures of the hatch. First set are before cleaning it and the second set is after I cleaned. Note it is winter still.
https://photos.app.goo.gl/G6FR7CcJbWDBHzoe6