New FX4 since October........Has anyone looked at the muffler.......total rust!! Is this normal???

Greg

 

Mine is just starting to show rust at the front 3 inch's of the muffler. its been thru alot of salt so far this year
lets hope they burn thru before 3 years are up )

 

This is funny, I just asked you if you had a rusty muffler in your engine compartment post.

YES!

I know it sounds knit picky, but that puppy is rustier than the stock muffler on my '97. It wouldn't be quite as bad if it weren't so highly visible. It makes the truck look ten years old as you walk up to it.

I guess it may be time to put a Borla Stainless system on it

 

Yep...rusty muffler here, too. I've only had the truck about 3 weeks and the muffler and drive shaft are total rust. I was told by every Ford owner I know that it's "normal"???

 

I've got an '03 not an '04, but that was one of the first complaints I had about mine. The driveshaft, steering box and Steering knuckles (I think, it's late, and I'm tired) were all almost bright red they were so rusty when I got the truck...

 

Yeah me 2 it sucks because that's the first thing I see when I'm walking up to the truck. Pisses me off

 

Hey guys, you may want to try a product called "Rust Converter" from Gempler's. They are on the web. [I have NO affiliation]
I have used this product for years on my snowplow,garden tools,etc. It bonds with rusty metal and leaves a nice black finish on the metal. It is paintable. I don't remember if it is heat resistant though. Maybe you could also try using high heat engine paint. I'll use one or the other on my truck for sure.

regards
Mark

 

No rust here bright shinny I can see myself in the stainless steel Magnaflow system. I walk up to mine every morning and say cool.

 

I don't know if it would work, or be possible with the heat issue, but I recall a post on here where someone bought a small can of Herculiner sealant (same stuff used for spray-in liners) and he coated all the underside parts of his new truck with it that looked like they would rust. He showed pics and it looked good.

 

Note1: The above quote is from another thread titled "Stock Exhaust Question". jaguar63 states the muffler is 304 SS. Here is the comment I put on that thread which I'll also make on this thread. What I experienced seems to be the case with what most others on this thead have experienced.

Note2: Also check out thread ?"2004 FX4 Exhaust On Muffler"

I have an '04 build date of 07/20/04, bought it in 12/04. I'm in WI where there is a lot of salt on the roads. It's been through about 1/2 a winter, and my muffler looks like it's going to rust apart (all of it, not just parts of it). I was shocked when I saw this and figured Ford must have chinsed on the exhaust system. If the muffler truely is 304 SS, why all of the rust in such a short time? I've never had a car or truck that had a muffler rust out so fast? Something isn't right? Anyone else (in areas where salt on the road is common) experience rust in such a short duration?

Based on what I've seen on this and the other two 'rust' related threads is exhaust/muffler rust is normal. Perhaps not acceptable, but normal. If it's normal and lasts as it should, it's only an irritation. However, my question still stands, if the muffler is 304ss, why so much rust in such a short time frame?

 

I didn't notice any rust on my bumper till my brother pointed out to me that it was coming through where the road lights are. Needless to say, I'm not thrilled that a truck, barely approaching 1 year old, has rust. I drove a 88' chevy truck for 10 years and the bumbers never rusted. After further inspection of the truck, there is rust everwhere; i.e. drive shaft, etc.

 

For the love of god people.... rust underneath your trucks is NORMAL!!!! Is this the first modern vehicle you've ever looked under?!

Rust on the body is a dealer & warrenty issue... it can happen with flaws in the manufacturing process. Get over it.

 

i couldnt have said it better myself. these threads are ridiculous. have you checked your driveshaft. that should be nice and rusty also.

 

Is the driveshaft made out of SS - I don't think so. The basis of the thread is if the muffler is SS, why are they coated with rust within a few months. I'm not talking about a few spots, my entire muffler is brown within a few months old. SS 304 should not rust that quickly. Something doesn't add up? And yes, I've had and looked at other brands of new trucks where the muffler is not rusted! If the thread is so ridiculous, I'm guessing your an expert in SS and thus should be able to answer the question!

 

maybe ford was saying the internal components of the mufler are SS,,,,,

and 409 ss, come on, that's pretty rare......