It is a shame...but yes, I have experienced similar situations on two FORD trucks 98 and 00(although not my control arms). My 2000 was ordered direct from the factory and there was surface rust on a few things underneath. I made them look as good as new though. The rear differential on my 98 completely peeled off after only 7 months of owning it. I had to scrape, prime and repaint it.

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2000 F-150 XLT, 4x2, 5.4L Supercab, Superchip, Styleside, Black with silver two-tone, 3.55 rear, class III towing package with heavy duty cooling package, Heavy duty shocks, 4 wheel disk ABS, overhead console, sliding rear window, keyless entry, dark graphite interior, in dash CD, factory leather wrapped steering wheel, Pendaliner bedliner, K&N air filter, rubberized undercoating, cabin filtration system, Bugflector II, 5W-30 Mobil 1, engine build 10/4/99

 

My Expedition is brand new and I was shocked to see that the lower control arms are completely covered with rust. This is the part of the front end that connects to the back part of the front wheel's brake assembly. Is this something I should expect from Ford? Has anyone else experienced this? It's a same paying almost $40K and seeing so much rust.
Thank you in advance