Okay guys,

I am reluctantly creating this thread because it is very painful for me to find this out this stage of my ownership. I hate to be the bearer of bad news, especially on my own truck, and I’ll let the facts speak for themselves. Keep in mind that my truck was built on the 20th of April 2001 but I purchased it on the 21st of September. According to the dates, my truck has sat on my dealer’s lot for almost 5 months including transit time too. The truck had exactly 16 miles on it when I “bit the hook”.

BTW, this is my second attempt at creating this thread. The first one crashed on me after more than an hour of writing and creating links to the photos needed to support the text. I am just including the links to the photos this time where last time I included the photos in the body of the text. After submitting the post, and a message popped up telling me I had too many pictures or smilies. It said go back and delete some pictures or smilies and re-submit. Guess what, I was unable to recover from that message and lost the whole thing and that sucked. What makes it worse is I’m trying to post info that is related to poor workmanship and quality and now I have to do it all over again just so everyone else can benefit and maybe help either themselves or me.

I submitted an email to the Webmaster and nothing was said and I got no help on that problem. In the future, I’m going to create every long reply or thread creation in Microsoft Word and then just paste it into a new thread or a reply to an existing one. If I save it on my PC, and something happens on the F-150 Online site, then I will have a back up. Whew, that was a lot just to tell you how easy it is to lose lots of work on the F-150 Online site.

Now to get to the real reason I’m writing this in the first place.

I was removing my front center console to install my Kenwood 10 disc CD changer. The entire console is held in with four big screws coming up through the floorboard. There are four studs that are spot welded from underneath the truck. I removed the front console cup holder and there it was, one of the mounting flanges was cracked/split.
https://www.f150online.com/galleries...2-452-3360.jpg

I tried to remove the screws and had no problem except for the one that had the cracked/split flange. The stud was turning while I was trying to remove the nut. This is when I knew something was really wrong here. I managed to hold the stud with a socket and turn the nut with a wrench, all the way I might add. I was getting pissed right about that time but of course I had to proceed. I finally got the console out and on the ground and started looking real hard. Here is a link to the picture that shows the loose stud:
https://www.f150online.com/galleries...2-452-3359.jpg

To give you an overall perspective of the console with both front flanges exposed, visit the following photo link:
https://www.f150online.com/galleries...2-452-3361.jpg

As you can see from the previous photo, there was quite a bit of heat applied to the area of the cracked/split console flange. I think this was due to Ford trying to fix the loose floor stud by welding it on the production line after the console had already been installed. Also, on the first picture, there are a few signs that the paint in the area of the flanges is burnt and bubbled up, again another sign of adding heat after the paint was applied. I really don’t know how this can be fixed as I’m fairly sure someone would have to remove the transmission along with a butt load of other stuff just to fix that darn weld in stud. The paint that is burnt could be easily fixed as well as getting a new console inner shell to replace the cracked one.

Now, to add insult to injury, I noticed after eight days of ownership that the front leading edge of my hood paint is all screwed up, no pun intended here. Looks to me like someone at the paint shop just wiped it with a rag but only they would know what happened. Either way, it looks like crap to me and it will get it fixed one way or the other. Looks like I’m going to need to get the hood re-painted to fix this one. Here is the link to the picture:
https://www.f150online.com/galleries...2-452-3358.jpg

Hold on, just when you think it couldn’t get any worse, I noticed that there was another problem right around the front passenger side head light bezel. I think it’s called a bezel but it’s the molded piece that houses the light assembly and is just below the fender. The point to notice on the photo is the contact between the bezel and the tip of the fender. Looking at the photo, find the point on the fender and move an inch or so to the left and down just a little and you will see that the paint is coming of from being chafed. To me, it looks like there is some sort of serious misalignment going on in this area. I’m note sure how this could be fixed because if all the parts are the same then replacing them will not change anything here. Here is the link to the photo:
https://www.f150online.com/galleries...2-452-3365.jpg

Please comment on what you think and let me know if anyone out there has experienced anything similar. Please take into consideration that I love my truck and I don’t want to bash Ford but poor quality is very serious IMO. I work in manufacturing and quality is almost everything because if you don’t have it you will suffer in the long run from lost sales and loyalty. P.S. All the photos plus some more can be viewed on the link in my signature to my personal gallery.

I’m adding my signature ‘cause I’m still very proud of my truck and to be an American.
DaveMan

 

In regard to the paint I would say it looks like the white spots are from where someone wet sanded the hood. Your truck must have been damaged in shipping. I can only speculate that the reason your truck was on the lot so long was because it was at the body shop most of that time. Probably waiting to be repaired and possibly a settlement payment from the insurance companies involved.

I really hate to see that. Might have been just a scratch ... but just to be safe I would check the front end over real well for any other tell-tell signs of damage repair to the front end.

Regarding the loose weld and crack ... back in the early 80's Ford manufacturing plants where notorious for over torquing anything related to a screw. (Unlike GM, where have the screws came out after a few months). I have not notice that problem with my Expy or S'Crew.

I have only noticed one issue with regard to quality on my truck. The paint color does not completly cover the corners at the bottom of the deep grooves on the roof. I have not taken it in yet, but I will soon. (There have been threads on this issue)

Good luck and I wish you the best ...

 

Thanks for the tips screwfun,

I felt where the paint problem is on my hood and it is very rough, almost like it has dirt or sand under the paint. I know what it looks like after sanding is done and it looks nothing like that. It really does look like it was smeared with a rag after being painted.

With that light bezel thing, you maybe onto something that it might have been damaged during shipping. My dealer told me that if any repairs are done after receipt of a vehicle from Ford that they must disclose that info but if done at the factory Ford has no obligation to tell anyone, not even the dealer.

As with the floor screws, I think the weld stud failed during tightening and they tried to fix it after the interior assembly had started. Hence the bubbled paint near the studs and the melted console flange. To me, they should have put this truck over to the side and fixed whatever was wrong becasuse now it's gonna cost them a he// of a lot more than if they would have fixed it in their factory.

Thanks for the good wishes,
DaveMan

 

I completely agree with screwfun, unfortunately. I certainly would be going over the front end of that truck very closely looking for any other signs of repair.

Hope you can get it all fixed up. I've had my KR since June and I've thoroughly enjoyed it.

 

Daveman,

I am sorry to hear you've had a miserable experience so far. I'll give you my "If I were you...":

You're truck has been repaired. The paint on the hood bumperpost should be black, not exterior-colored oversprayed. For that alone, I would take it back and demand a new truck. You don't know what kind of damage was done to the front...and apparently because they did not notify you, the dealer doesn't either. I would be tempted to consult with a lawyer first.

Give the dealer the chance to make things right...meaning, a new truck. If they do not, then you can raise holy hades with Ford and the dealer; also notify one of the local TV network's consumer advocates. I'm sure the dealer doesn't want the negative media coverage on this one.

 

DAVEMAN, Ara52-

Actually, the hoodpost should be bodycolor in this case. On some vehicles, Ford puts the overslam bumbers (posts) in the body-build area in Kansas City and they go through paint (I have seen them firsthand). On most vehicles you are right, they shouldn't have color. Just to be sure i checked my truck...same color KR built same month....and same body color paint on posts.

That may not say it WASN'T repaired, but it isn't proof by itself that it was. that sucks DAVEMAN,,,I'll write more later....gotta run.

BTW....new Email is same as old except: @onebox.com instead of @zdnetonebox.com

Logical

 

I had a 99 EB expy which had superb fit and finish. My wife had an 01 Escape. Fit, finish, materials were utter rubbish. Got rid of that piece ASAP. I jumped on an 01 screw lariat and I am utterly dismayed by the lack of Ford quality. They have slipped, for sure. My truck has 3K miles. Already i have a couple of spots in the paint I found that bubbled up. The moulding around the driver door has come off repeatedly. Having to take it back to dealer. The AC is marginal at best. My Expy would freeze me out of the cabin. The door handle has a problem. Can't quite figure out why it is so loose. The driver mirror insert is loose. It vibrates quite a bit. Several peices of moulding in and around the car fit very poorly. The little plastic piece covering the window controls on the driver side keeps popping off.

It is difficult for me to believe that Ford would let this happen, but they have. Believe it or not, I turned down 2 other screws on the lot because they had significant paint issues. The dealer offered to discount the truck and repaint it, but they shouldn't have to.

As bad as Ford is, Cheby and Dodge are far worse, so I lease I can console myself that way. This is about my 5th or 6th Ford vehicle. I was very loyal up until now. If Honda does in fact make a 4 door full size truck as rumor says they are, I might have to reconsider my brand loyalty.

Ken

 

I just went outside and looked at my overslam posts and they are painted also. Daveman, I feel bad for you, you seem like a guy who is way into his truck. I would be inclined to return it if I were in your shoes (and I might be once I start in on modifying mine). You are the one making the monthly payments on Your truck, and you should be happy with it. Get on your dealer and Ford and don't quit until you are satisfied, either with repair or replacement. Good Luck.

 

Daveman,

If it were me, I'd take the info you've worked hard to document to a lawyer, and start talking LEMON. The body alinement in your
headlight bezel picture is terrible. My 99 is about as perfect as I've seen in a vehicle, so I'd be in agreement that your truck may have problems that the dealer knows about and is trying to slide by you. I wish you luck, you've got a fight ahead of you.

 

Daveman,

I know how you feel since I am on truck number two right now. My dealer gave me a new truck about two weeks ago to replace my first one that needed a new engine in it.

My second KR had paint problems too. The roof of the cab had a rough feel to it like sand was under the paint or something. I caught this during the vehicle inspection. The dealer had their detail guy buff it out. It looks good now.

Well after washing the car for the first time today I noticed sand like particles in a few other places on the truck. It is not too bad so I probably won’t ask the dealer to do anything about it. I would rather not have any buffing done for the fear of making things worse especially on the highly visible side panels. I plan to clay bar the truck later this week.

My truck was built on 4/01 so maybe we had the same painter.

Good luck.

Art

 

unfortunately ford's paint quality (at least at the supercrew plant) sucks. my xlt s-crew has many small paint flaws that i've decided to do nothing about since i'm trading it in this month for a newly ordered kr. probably the biggest paint flaw is around the front lip of the hood where it is very rough...there are small runs and what looks like dirt in the paint in a few other places...

 

Dave, I read your post all the way through without looking at the pictures and thought that they sounded minor. Then I looked at the pictures and the first thing that I said was " this truck's been hit"!
I've owned my truck for almost 7 months and 16,000 miles later and have not had 1 problem or complaint.
The paint is perfect, runs perfect, no tranny problems, body panels fit perfectly, (yes I'm knocking on wood).
Sorry to see and hear about all the problems. Hope your dealer takes care of you.
Odd that it sat on the lot for that long without being sold. The dealer I bought from had two on his lot, a Chestnut and a Charcoal Blue witch were gone almost immediatly. I ordered mine to get the Estate Green. Good luck.

 

daveman,

i can feel your pain, in a way. i'm somewhat of a perfectionist too! it's hard not to be when you plunk down 30k+ for a vehicle! what is even more irritating is that the japanese build sub 20k cars that have nearly perfect fit and finish, and here i sit with an almighty ford 4x4 that had a misaligned hood (until dealership fixed), kinda crummy paint job, and a cd player that has been replaced twice. i must admit, even though i really like the s-crew, ford could do a better quality 1 job...

 

Very sorry to hear of your problems... I know how it feels when your favorite toy is complete perfection.

Unfortunately, I have to agree with you and others about deteriorating build quality. My 97 Supercab was absolutely flawless... great paint, perfect fit, and an engine and transmission that were tight as a swiss watch. Not so with my 2001, bought 6/30/01. Oh, it doesn't have quite the problems of yours, but, it just isn't as solid, and I'm so convinced that the tranny will fail on it that I bought an extended warranty.

Ford needs to get back to quality control.

 

Thanks for all the support gang,

I went to see my dealer today and they said they would do whatever it takes to make me happy, except replacing the truck. They feel that any of the items I mentioned could be fixed at their store. I mentioned that the weld-stud wouldn't be able to get fixed without a he// of a lot of stuff removed, like the transmission, transfer case etc but they said they would have to look into it in more detail.

I would rather just get a new console and fix the headlight bezel to start with and go from there. I'm a little hesitant to have the hood paint repaired since I know that the whole hood would have to be repainted and it will probably never completely match after that. As far as the weld stud, I doubt there is anything that can be done short of getting a new truck and right now the dealer says that is not one of my options. I thought I had another problem with the rear cab mounted tail light but now I'm not sure. I noticed that when I wash it that water runs behind the light. I thought it was going inside the fixture but after removing it I think the fixture is sealed and the water is just going around inside the lens but not into the sealed part. I'll keep an eye on that for a while.

I called the Ford 800 hotline number and told them my story too. They were not excited even in the least and the Spanish accented speaking attendant seemed fairly knowledgeable but just was writing as I was talking. She asked me several times, is that all, is that all, is that all, and what did the dealer say several times too. I kept on telling her that the dealer said they would do whatever it takes to make me happy except no new truck. I insisted that I wanted them to know first hand of the issues and to make a report. I told her that I was concerned that I keep wondering what else am I going to find. What will happen to the value of my truck after I have to disclose that paint and bodywork had to be done during my ownership? Some prospective buyer would be reluctant to buy thinking that there were other problems. I think Ford should give be some sort of retribution to offset the perception of reduced value in addition to actually fixing my truck to my satisfaction. To be totally honest, I don’t think anyone will ever be able to fix that weld stud to my satisfaction even though it probably will never make a difference except in my mind.

To dredge up some old stuff, I also told them that my radiator was too small for the towing package, 1.02 vs. the advertised 1.42” or the 2.02” one that comes with the Expedition’s setup with a towing package. I know that Ford has made statements about the radiator size to a lot of screw owners but at this point I’m going for everything that bothers me.

I’ve given Ford the benefit of the doubt but now all I have is doubt as to why they changed their minds on installing the bigger radiator in trucks with a tow package.

My ’00 4x4 Super Cab was the best vehicle I had ever owned and the quality in that truck was no doubt better than any I had ever seen. I drove that truck for almost two years and never once had to even go to the dealer for the slightest issue.

Now the Screw quality is another story, I think Ford’s motto of “Quality is Job 1” has slipped to “Quantity is Job 1”. IMO, quality has slipped into second place over deliveries, too bad ‘cause it’s going to cost them in the long run even if they fix whatever is wrong. People never forget getting screwed and I don’t mean a Super Crew either.

DaveMan