Saturday was a day of reckoning for my Ford Freestar. As detailed in an article I wrote last week, my Freestar required a trip to the dealer to repair rust related issues that affected the rear wheel wells and the third row seat latches and the cost of the repairs were covered by Ford under a recall issued earlier this year. I promised then that, once the repair was completed, I would report back to you on how everything turned out.
As you may remember from that earlier article, the damage to the van was fairly advanced. The area around the seat mounts was encircled with corrosion and, in some places, had rusted to the point that there were actual holes between the wheel well and the interior of the vehicle. The affected area had been concealed under a plastic panel so I had not noticed the issue earlier, but I had noticed the van felt and smelled damp. How the whole piece had stayed in place I have no clue as it seemed to me at the time I could have pulled the seat mount out with my bare hands.
As usual, my local Ford dealer was excellent and scheduled the repair as quickly as they could. They took it in after work on Friday night, completed the repair on a Saturday and I had the vehicle back in my garage that night. Once again, Ford deserves accolades for their customer service and I came away quite satisfied with the transaction.
On Sunday morning, I went out to the garage and took a good look at the work done. From the wheel well side I could see where a new piece of sheet metal had been grafted onto the inner fender well. The edges appear to have been carefully caulked and the whole thing covered over with rubberized undercoating. To my eye it looks to be a neat and efficient repair.
Inside the van, I once again removed the plastic panel to examine the backside of the repair. The most obvious thing the Ford techs have done is to totally cut out the rusted area. It appears as though they did the work with a pair of tin snips, nibbling away at the area one bite at a time and leaving a series of sharp metal teeth along the edge of their cut. Several sheet metal screws have been used to affix the panel and a large steel band has also been added to reinforce the seat mount. Besides the sloppy cut, which would have been neater and easier had they used a dremel or a sidewheel cutter, the repair seems to be a good one. Given that it was all done on the company dime and that all the sharp bits are hidden behind a thick plastic panel where they should never come into contact with soft human skin, I am satisfied with the work. Of course, since I am not a body and fender man, I’d be interested in everyone’s comments, too.
To me, however, there is a larger issue brewing. This whole experience of finding massive quantities of hitherto unexpected rust has left me questioning whether or not hanging on to the Freestar for another year is really worth risk. I wonder now just what other parts of the vehicle are suffering similar issues and what the results may be if we have an accident. There are, I note, a few places around the body where rust bubbles are forming and I have over the past year assiduously attacked the red stuff wherever I have found it, in particular along the lower edges of the vehicle’s doors. With my eventual departure from Buffalo now less than a year away, I am thinking it may be time to replace the Gray Lady and I have a pretty good idea what we are going to end up with.
Am I wise to make a move or just worried rat trying to jump a holed ship that isn’t actually sinking? You tell me.
Thomas M Kreutzer currently lives in Buffalo, New York with his wife and three children but has spent most of his adult life overseas. He has lived in Japan for 9 years, Jamaica for 2 and spent almost 5 years as a US Merchant Mariner serving primarily in the Pacific. A long time auto and motorcycle enthusiast he has pursued his hobbies whenever possible. He also enjoys writing and public speaking where, according to his wife, his favorite subject is himself.