I had a ford service tech warn me last week that the oil pan on my 2003 PSD was almost rusting a hole in it. 28,500 miles on it.
Yeah I live in New York State where they salt the roads in the winter but I have had Ford trucks for years and never had this happen.
He told me to wait a couple of months and scrape it until oil starts to seep, then bring it in for new oil pan under warranty.
Why could'nt I bring it in now to do it? Does it actually have to leak to get it replaced. Anyone have this happen??

 

Landstroker

This is a common problem on the PSD.. I have been told by many mechanics even my dealer.. Also this has nothing to do with salt.. They tell me it rusts from the inside out.. When it happens the service rep told me to look for a bubble under the paint that is the first sign.. He said they coat the pans with some material to deaden the sound.. I forget exactly what he said..

I would bring it in right away and have it changed.. If you wait then you may forget to bring it in before the warranty ends or (extreme case) the oil pan may leak all the oil out and then your motor would seize up..

If they found it now they should fix it now....

 

There is a TSB 05-20-3; oil pan corrosion 6.0 & 7.3 engines. This TSB is dated 9/22/05.

Basically they prep it and apply a Motorcraft anti corrosive coating PM-13-A.

 

I just changed the oil in my company truck. 2006 PSD F250. Got in about 30 days ago. Though I am no expert I could swear that the oil pan was plastic. I did not have that much time to really check it out. but tapping on it with my wrench did not make the noise I usually hear.

 

My painted front bumper was rusted badly after one winter. The dealership took a quick look at it and said it is rusting from the inside out. You could see what looked like pimples in the paint, then they broke it started to rust. The funny thing was how quickly he knew what it was. I asked him if I am going to see rust every winter and he said that now that they know about it, they may make an exception to fix it, even if out of warranty. They warrantied it and it was repainted. What is up with all of this rusting?

 

'Most times', rust pitting and blistering on painted bumpers and even the coated oil pans ect. is from road grit/sand/abrasion and small 'projectiles' that make 'very' small pinholes 'and lots of them' in the painted surface, and/or from painted surfaces that are 'mil thin' from application on the edges, or complete areas that don't give enough coating protection from harsh environments/corrosives.. Either water, or water/salt will collect in the tiny chips and will rust 'under' or along the paint edge until blisters develop and 'pop' the paint topcoat from the continually deteriorating surface.. Most primers (if used) are somewhat porous as well, and can wick/absorb mosture under the topcoats if the surface coat is broken open.. And with some primers, adhesion of the topcoat and/or 'lifting' is a problem if the paint edge is left open to the elements from either a chip or scratch..It's most likely not a matter of rusting from the inside out, but rather rusting from a surface destruction barely visible to the naked eye and/or sometimes thin application like on the bumper coatings.. Plus another factor is, with the 'never ending' restrictions for the use of volatile organic compounds (VOC's) that make for tough/durable paints and coatings, many coatings can fail early and require new application/s.. Witnessed by the 'many' cars and trucks you see with large 'streaming' primer exposure, and peeling clear coats on late model year vehicles.. If my truck (pan) were in a salty/corrosive environment and showed early signs of paint failure, I'd clean it off from oil/rust, cover for overspray, and give it a good heavy coat of 'Rubberized' Undercoating.. Superior high build, excellent adhesion, spray application for complete coverage/access, flexable, and 'does not' chip/peel..

.................HP.....................

 

I'm telling you this slurrey, water/salt spray.....corrosive, anti-icing, new age formula gell that Ohio is using will leave just the tires and delete the rest of the truck.......I have about had it trying to keep this truck from damage. If I can make a point to someone in upper management at ODOT maybe we can survive another winter.

Exactly what Hayapower says, once you damage or chip the metal, the rust is on its way.

 

I would love to challenge that statement.