Could someone possibly shed some light on how or why this could ha e possibly happened. Passenger front rotor

 

Either a manufacturing defect, or possibly something got between the rotor and the caliper. Inspect the caliper for any damage on the bottom side.

 

This is also a second hole in the same rortor

 

Excess porosity in the casting, it happens sometimes.
Replace it and go on, nothing much else to do about it.
If still under warranty, dealer should have no issues getting it warranted.

 

so the truck has 30000 miles and is under every warranty since brand new but when calling different ford dealership some say it should he covered and some are saying it won't be covered.

 

Typically "wear parts" like clutches, brakes, etc. are only covered for 12 months or 12,000 miles.

 

That looks like a defect, not wear.

 

Be grateful the front wheel didnt lock up at speed when it came apart.

 

From what I've heard, if the lug nuts aren't tightened evenly or to the right torque, it can cause the brake rotor to warp. When that happens, you get uneven surfaces, which leads to more wear and tear and could eventually cause a failure. It's best to make sure they're tightened just right to avoid those problems. I always double-check after getting my tires changed

 

so you are right about that cause it's been like this for awhile with no indication of this problem. No vibration nosie or anything never would have known if I didn't get my tires rotated yesterday

 

nothing is warped the rotor surface witch meets the brake pads is in great shape it's only the area of witch is in the picture

 

should be a warranty since this is a casting failure.

The tire and rim will be inspected to ensure nothing was lodged or any other causes.

Do not drive it, have it towed.

 

I did notice that both holes are aligned to the bolts holding the hub vs between the bolts.
A coincidence, possibly, but I would tend to think that the inside surface where the hub bolts sit might not be square or smooth. In turn that put undue stress around the bolt hole.
Just thinking out loud.

 

That has been that way for a while based on the rust. Has anyone done any service that would have required removal of the rotor? Maybe someone got over zealous trying to remove the rotor (surprised it would be with only 30K miles). Have you done any off roading and maybe a rock or something got behind the rotor or between the rotor and caliper? I can't imagine it was this way when delivered. The crack looks like it was pushed out from inside. If it were a casting issue that would shown up in the machining. Might be machined to small on the inside or the hub it's on is to large and as the rotor was tighten on it wedged on the hub and busted out the rotor in two locations.

 

But, that is a defective part, not wear related.
It definitely should be a warranty fix, if a dealer service manager says no, then you are at the wrong dealer.