Axle Rust on 2021 F-150: My Method For Treating It

[Another Ford]

Again, it seems Ford or their supplier is missing a process and Ford is expecting this to be OK to the end customer. A properly post processed differential housing should never rust sitting in a field that's nowhere near a salt source.
By the pics above it looks like an attempted CYA.
This should be a non-deliverable...
Many of us mod our trucks with lifts with custom shocks and wheels; Looks so nice on a $70k rust bucket.
Vent over

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[Kefoster2]

Personally, I don’t think Ford will do anything about the rust issue. My assumption is that they will come up with a fix for trucks that have yet to be built but they won’t do anything for trucks that they already sold. I negotiated an additional $200.00 off when I picked up my truck to cover the cost of rustproofing / undercoating. None the less, I went ahead and cleaned up the rear axle and exhaust hangers myself. That way I know the rust is gone. It came out so well that I really don’t need to get the truck rust proofed but I plan on keeping it for a long time so I will still get it sprayed. Fortunately, my exhaust pipe and muffler are pretty much rust free. The ends of the axle where the rotors are wasn’t bad either.

Below are a few pictures of the process that I did. I’m not endorsing any products; I’m just showing you what I did and what worked for me.

I used Rust-Oleum Rust Dissolver spray. I chose this because they state it will remove light rust without removing paint. If the rust is heavier in some areas the paint will be gone and you will be left with bare metal after using the dissolver. I also used a dish / pot scrubbing brush and Rust-Oleum flat black paint. I purchased all three items at Lowes. I also used CRC Marine Corrosion Inhibitor which I bought on Amazon. This is awesome stuff in my opinion. Its not pictured but I used a little primer on a few bare spots on the axle where the paint was gone. While priming bare metal is the best practice you could still just paint the axle and seal it with CRC Marine. The CRC product will stop the rust from coming back. Just let the paint dry a full 24 hours before applying CRC Marine. I also used a small piece of cardboard to block overspray. You could tape off any areas that you are concerned about but I didn’t. CRC Marine has a slight brownish tint when it dries. If you spray it on axle nuts / bolts it will add a brownish color. Just be aware of that if you use it.

My axle is now rust free and I don’t have to be concerned about it. You could fight with Ford or your local dealer about it and wait a very long time only to potentially have nothing done. Meanwhile the rust will continue to get worse. I decided to fix the problem myself and move on. On a side note, if you question if you can do this yourself, I’m 54 years old and I’m a big guy (6’4”, 285lbs). I did this on a gravel driveway lying on pieces of cardboard. I was able to slide under the truck and do this without jacking the truck up (though it was a very tight fit). I have 20” wheels. It sucks doing this but once you’re done you don’t have to be concerned about rust anymore.

Just thought I’d pass this along in case anyone is considering doing this themselves...

I followed this process and it works great.

 

[MamboMinnow]

Personally, I don’t think Ford will do anything about the rust issue. My assumption is that they will come up with a fix for trucks that have yet to be built but they won’t do anything for trucks that they already sold. I negotiated an additional $200.00 off when I picked up my truck to cover the cost of rustproofing / undercoating. None the less, I went ahead and cleaned up the rear axle and exhaust hangers myself. That way I know the rust is gone. It came out so well that I really don’t need to get the truck rust proofed but I plan on keeping it for a long time so I will still get it sprayed. Fortunately, my exhaust pipe and muffler are pretty much rust free. The ends of the axle where the rotors are wasn’t bad either.

Below are a few pictures of the process that I did. I’m not endorsing any products; I’m just showing you what I did and what worked for me.

I used Rust-Oleum Rust Dissolver spray. I chose this because they state it will remove light rust without removing paint. If the rust is heavier in some areas the paint will be gone and you will be left with bare metal after using the dissolver. I also used a dish / pot scrubbing brush and Rust-Oleum flat black paint. I purchased all three items at Lowes. I also used CRC Marine Corrosion Inhibitor which I bought on Amazon. This is awesome stuff in my opinion. Its not pictured but I used a little primer on a few bare spots on the axle where the paint was gone. While priming bare metal is the best practice you could still just paint the axle and seal it with CRC Marine. The CRC product will stop the rust from coming back. Just let the paint dry a full 24 hours before applying CRC Marine. I also used a small piece of cardboard to block overspray. You could tape off any areas that you are concerned about but I didn’t. CRC Marine has a slight brownish tint when it dries. If you spray it on axle nuts / bolts it will add a brownish color. Just be aware of that if you use it.

My axle is now rust free and I don’t have to be concerned about it. You could fight with Ford or your local dealer about it and wait a very long time only to potentially have nothing done. Meanwhile the rust will continue to get worse. I decided to fix the problem myself and move on. On a side note, if you question if you can do this yourself, I’m 54 years old and I’m a big guy (6’4”, 285lbs). I did this on a gravel driveway lying on pieces of cardboard. I was able to slide under the truck and do this without jacking the truck up (though it was a very tight fit). I have 20” wheels. It sucks doing this but once you’re done you don’t have to be concerned about rust anymore.

Just thought I’d pass this along in case anyone is considering doing this themselves...

Thanks for posting your solution. I performed today on my 2021 PowerBoost XLT. I took it in to dealer at 35k miles for two recalls and asked if Ford would ever issue a recall for this as well.

They said no and my 3/36 warranty is about to expire. So, I decided to take care of it myself now.

 

[dwade62]

Personally, I don’t think Ford will do anything about the rust issue. My assumption is that they will come up with a fix for trucks that have yet to be built but they won’t do anything for trucks that they already sold. I negotiated an additional $200.00 off when I picked up my truck to cover the cost of rustproofing / undercoating. None the less, I went ahead and cleaned up the rear axle and exhaust hangers myself. That way I know the rust is gone. It came out so well that I really don’t need to get the truck rust proofed but I plan on keeping it for a long time so I will still get it sprayed. Fortunately, my exhaust pipe and muffler are pretty much rust free. The ends of the axle where the rotors are wasn’t bad either.

Below are a few pictures of the process that I did. I’m not endorsing any products; I’m just showing you what I did and what worked for me.

I used Rust-Oleum Rust Dissolver spray. I chose this because they state it will remove light rust without removing paint. If the rust is heavier in some areas the paint will be gone and you will be left with bare metal after using the dissolver. I also used a dish / pot scrubbing brush and Rust-Oleum flat black paint. I purchased all three items at Lowes. I also used CRC Marine Corrosion Inhibitor which I bought on Amazon. This is awesome stuff in my opinion. Its not pictured but I used a little primer on a few bare spots on the axle where the paint was gone. While priming bare metal is the best practice you could still just paint the axle and seal it with CRC Marine. The CRC product will stop the rust from coming back. Just let the paint dry a full 24 hours before applying CRC Marine. I also used a small piece of cardboard to block overspray. You could tape off any areas that you are concerned about but I didn’t. CRC Marine has a slight brownish tint when it dries. If you spray it on axle nuts / bolts it will add a brownish color. Just be aware of that if you use it.

My axle is now rust free and I don’t have to be concerned about it. You could fight with Ford or your local dealer about it and wait a very long time only to potentially have nothing done. Meanwhile the rust will continue to get worse. I decided to fix the problem myself and move on. On a side note, if you question if you can do this yourself, I’m 54 years old and I’m a big guy (6’4”, 285lbs). I did this on a gravel driveway lying on pieces of cardboard. I was able to slide under the truck and do this without jacking the truck up (though it was a very tight fit). I have 20” wheels. It sucks doing this but once you’re done you don’t have to be concerned about rust anymore.

Just thought I’d pass this along in case anyone is considering doing this themselves...

Did you need a degreaser?

 

[Mosey]

I used Rust-Oleum rust remover followed by POR and POR top coat. I must say that spraying looks better, but since I can’t see it, as long as it is protected that is all that matters.

 

[midnightmogwai]

I appreciate these steps. I’m dealing with this on a brand new friggin ‘23. I didn’t even think to look under the truck. Got caught up in the moment. Messaging with the dealer now but unsure anything will come from that. Glad I have a plan B. Frustrating.

 

[Cobraman428]

I appreciate these steps. I’m dealing with this on a brand new friggin ‘23. I didn’t even think to look under the truck. Got caught up in the moment. Messaging with the dealer now but unsure anything will come from that. Glad I have a plan B. Frustrating.

My dealer told me to get a quote from somewhere and they would pay for it. I couldn't find anyone to do it. LIne-x etc. I just ended up doing it myself.

 

[Spindrive]

Finally got around to this… no before pictures but it was bad.

thanks for the tip…

hows it held up since doing this OP?

 

[c79453]

Followed a similar method to the previous posts. This was on a new Kansas built 2023 F150. Build date was 10/23 and I took possession of it on 1/24.

Also curious to see how the trucks from the previous posts are holding up over the past 1-3 years?

 

[LFRoss]

Finally got around to this… no before pictures but it was bad.

thanks for the tip…

hows it held up since doing this OP?

Did you go all the way out to the shock mounts and the brake rotor covers? Also what did you do to keep from spraying the nuts for the I bolts and wiring harness?

 

[Blue22]

After almost exactly 2 years, mine is still looking good.

 

[LFRoss]

After almost exactly 2 years, mine is still looking good.

I have a 2021 that looks like it has been taken off road and never properly cleaned underneath which has started a decent amount of rust. I think going to have mine professionally cleaned and then do the rust treatment

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