2024 XLT Body/Sheetmetal Issue…Any thoughts??

[Deleted member 8845]

Hello! I am new to this forum, and recently took delivery of my 2024 Ranger XLT on June 20th, 2024.

While detailing the truck for the first time, I noticed a small dimple in the sheetmetal on the drivers side lip moulding. I can best describe the area in question is directly below the “B” pillar, and about two inches back from where the rear door meets the front drivers side door. The questionable dimple area was originally smaller than the size of a pea at first, this was about three weeks ago. I regularly wash my vehicles and didn’t think much of it other than it was a minor flaw from the factory. Unfortunately, I am concerned what I thought was a minor blemish might be worse.

Around two weeks ago, the small dimple turned into a small crease which had became noticeable to the naked eye. This weekend, Saturday July 6, 2024 while detailing the truck, the crease is now more pronounced, along with where the sheetmetal at the “B” pillar base meets the lip moulding it is now buckling outwards. The outward buckling on the vertical base of the “B” pillar is about 2 1/2” in length and 1 1/2” wide at its base, while the crease on the lip moulding is buckling inwards. The inward buckling crease has grown in size to about 7/8”. The picture with the red circle is the outward buckling, the red arrow shows the buckling inwards. Besides the drivers side crease, I discovered this past Saturday the passenger side lip moulding now has a small crease in nearly the same location as where the driver side crease is located.

The truck has an appointment with the Ford dealer tomorrow, July 9th. Unfortunately, my Ford dealer has only sold one other new Ranger, and that was a Raptor. I was the first to take possession of an XLT from my local Ford dealer right from the transporter. Has anyone else seen anything like this with their new Ford Rangers?

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[dfritz]

the photos are a bit too close for reference. Following this thread.

 

[Deleted member 8845]

the photos are a bit too close for reference. Following this thread.

I took a couple more pictures, but standing back a bit further for a better reference. The picture with the two vertical black lines were drawn onto the body as a reference point by the body shop manager. The dealership wants me to drive the truck for another week, then they are going to re-measure the changes.

I have owned the truck for 2 1/2 weeks, and rolled the odometer to 241 miles as I was pulling into the dealership parking lot this morning. Like I stated earlier, the problem area started as a barely noticeable small dimple, now it is in this stage in 2 1/2 weeks. The dealership didn‘t say much after today’s visit other than a formal claim has been opened with Ford. I did ask what the next steps might be if further examination needs to be done to see what the problem might be. The dealerships response was looking behind the exterior sheetmetal would need to be done and will be very intrusive. I am no vehicle expert, but intrusive sounds like the removal of the lower rocker panel is what was hinted at.

The Ford dealership is also watching the passenger side in the “B” pillar area as the rocker panel lip is showing signs of indentation as well. I’ll post more in the coming days on any changes or updates.

 

[fordtrks4ever]

Possibility A Cab not mounted on frame correctly causing stress.

Possibility B Cab was not manufactured correctly and has a weak area.

 

[Deleted member 8845]

Possibility A Cab not mounted on frame correctly causing stress.

Possibility B Cab was not manufactured correctly and has a weak area.

Thank you for sharing your thoughts. I feel this is what the Body shop manager may have been hinting at as well. I overheard a comment between the service and body shop manager that whatever is amiss, is it is possibly something major causing the stress points to make the sheetmetal deform. I really hope that is not the case, I am not too excited about my truck getting dissected to find out.

 

[Deleted member 5555]

Thank you for sharing your thoughts. I feel this is what the Body shop manager may have been hinting at as well. I overheard a comment between the service and body shop manager that whatever is amiss, is it is possibly something major causing the stress points to make the sheetmetal deform. I really hope that is not the case, I am not too excited about my truck getting dissected to find out.

Mine is the same way… I figure there are many more with this problem.

 

[Deleted member 8845]

8-7-24 Update

Today, I finalized the buyback process on my Ranger XLT and surrendered my truck back to Ford. After investigation, the visible exterior issues were much more concerning than a minor sheetmetal deformation. My understanding is the welds and panel bond had somehow become compromised and came apart. The area of truck which was affected was on the lower part of the B pillars on both the driver and passenger sides of the cab where the B pillar is connected to the lower rocker sub structure.

I am not upset or mad about giving up my truck, I am mostly sad to see my new Ranger experience such a failure. Although I am disheartened, I can’t say enough about the excellent customer service I received from Ford, and my local dealership. The buyback process is time consuming, but my customer advocates who were assigned to my claim at Ford were exceptional in their communication, and were superb in the assistance they provided when I had questions.

Because of the professional manner in how Ford addressed the problem and provided a resolution, I chose to purchase another new Ford vehicle. Unfortunately, it was not another Ranger. For now, I will need to be content with my new Ford Explorer as a my mode of transportation. Perhaps at some point I will give the Ranger another try? Right now I am a little apprehensive on jumping back into another Ranger for the time being.

If anyone is experiencing bulging or creasing of the sheetmetal dip edge on your Rangers, get it checked out. My dealership was able to diagnose the issue by scoping the internal cab structure with a camera. By completing the diagnosis, my dealership was able to see the failure points, and provide the information to the engineers at Ford. Hopefully the issue with my Ranger was the only one.

 

[Deleted member 5555]

8-7-24 Update

Today, I finalized the buyback process on my Ranger XLT and surrendered my truck back to Ford. After investigation, the visible exterior issues were much more concerning than a minor sheetmetal deformation. My understanding is the welds and panel bond had somehow become compromised and came apart. The area of truck which was affected was on the lower part of the B pillars on both the driver and passenger sides of the cab where the B pillar is connected to the lower rocker sub structure.

I am not upset or mad about giving up my truck, I am mostly sad to see my new Ranger experience such a failure. Although I am disheartened, I can’t say enough about the excellent customer service I received from Ford, and my local dealership. The buyback process is time consuming, but my customer advocates who were assigned to my claim at Ford were exceptional in their communication, and were superb in the assistance they provided when I had questions.

Because of the professional manner in how Ford addressed the problem and provided a resolution, I chose to purchase another new Ford vehicle. Unfortunately, it was not another Ranger. For now, I will need to be content with my new Ford Explorer as a my mode of transportation. Perhaps at some point I will give the Ranger another try? Right now I am a little apprehensive on jumping back into another Ranger for the time being.

If anyone is experiencing bulging or creasing of the sheetmetal dip edge on your Rangers, get it checked out. My dealership was able to diagnose the issue by scoping the internal cab structure with a camera. By completing the diagnosis, my dealership was able to see the failure points, and provide the information to the engineers at Ford. Hopefully the issue with my Ranger was the only one.

I stopped by my dealer today and they took pictures and sent them to ford. Mine looks like yours… I am bummed mainly bc of all the money in accessories I have. I should get a call Monday.

 

[Deleted member 8845]

I stopped by my dealer today and they took pictures and sent them to ford. Mine looks like yours… I am bummed mainly bc of all the money in accessories I have. I should get a call Monday.

Bummer! Like I stated earlier, the Ford claim advocates I worked with were exceptional, and very helpful. If you have questions, you can PM me as you go through the process if that’s where things go with your Ranger. Best of luck!

 

[Deleted member 5785]

Oh shit…..

 

[Deleted member 5555]

So… Ford has determined the robotic arm that puts the doors on was calibrated too low and caused the door to hit the cab and dent it. Mine, and some others are being repaired and warrantied. The op may have had something a little different… So I get to keep mine.

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