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I have an 05 Eddie Bauer Expedition, 10 months old, 10,000 miles.
(1) The trailer hitch inside measurement is 2 3/16" x 2 3/16 instead of 2x2. Anything I put in the hitch is sloppy loose, including Fords own rubber hitch cover. I have checked 5 other expeditions and they are all closer to the 2x2. Local dealer says they will do nothing, this is normal.
(2) Trailer hitch is rusting. I live in California where we have little water and no salt. Dealer says since the hitch is an iron part, it will rust, there is nothing to worry about and they will not do anything about it. I have never seen a trailer hitch rust at the joints in only 10 months.
Vewy Vewy Skwewey Sounds like a bad casting, I might think to check with a reputable towing products company and find out what the standard measurement for these are. It should probably actually have a D.O.T. spec.
I have an 05 eb expy with same problem. My hitch is very noisy cannot speak to rust as my expy is only 5 months old but the noise is enough to make me crazy. Have not done anything withdealer yet.
FYI all.. if you live in snow country you may be glad for the oversize receiver! the crud gets in there and it is tough to then get the ball mount in..
Since you say you live in a land without road salt...You got a problem. I'd take it to a second dealer for opinions. My 03 I put around 13000 miles on it with a bassboat in tow. The hitch was tight and the only rust was from where the hooks on the safety chains were attached to the holes that they hook into on the hitch assy....
my 05 has about 5000 towing miles on it and has 0 rust. The reciever is tight and almost no noise.
The only way it could rust is if the paint on it is cracked/faulty and allowing water to come into contact with the iron.
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