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I have rust along most of the seams underneath and along a couple in the engine bay.
I have been told by a couple of smash repairers that this is very common with no way to repair without replacing the body shell! In fact they were surprised I didn't know about it!!!
My vehicle is in as new conditon otherwise and has been well cared for (never been on the dirt or near salt). I have lodged a claim via my local unfriendly Ford dealer.
I am yet to hear about a rusting problem in AU's especially a common rusting problem! but if it happens you will find it out around here!
cheers
steve
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AU2 S-pack Owner: Silhouette Black, XR6 Wheels, Tickford Sunroof, C2R rear bar, Checker Plate Floor Mats, Chrome Door Sills, Blue Backlite Dash, Blue Painted Brake Callipers, Advanced Extractors, Magnaflow High Flow Cat, 2.5" Stainless Steel Mandrel Bent Custom Exhaust, Genie Muffler. Sony Explode 50w x 4 deck, Kenwood 140w speakers (front and rear), Boss 1200 watt Amplifier, 12" Orion Sub in custom box. More To Come!!
Yes I had noticed rust in the engine bay on used AU Falcon utes I was looking at in a dealers yard, quite a few of the vehicles had their bonnets up and it was obvious especially on the lighter coloured cars, I had also noticed that later models had seam sealer along the seam in the engine bay as does my XR6 ute which is a November 2001 build, I don't know when Ford started the seam sealer mod, cheers, Bill (ford jeepman)
ohhhhhh nooooooo! XD - XE nightmare returns???? aghhghghghh - not now...things are just starting to go our way
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Yes I had noticed rust in the engine bay on used AU Falcon utes I was looking at in a dealers yard, quite a few of the vehicles had their bonnets up and it was obvious especially on the lighter coloured cars, I had also noticed that later models had seam sealer along the seam in the engine bay as does my XR6 ute which is a November 2001 build, I don't know when Ford started the seam sealer mod, cheers, Bill (ford jeepman)
I went and checked out a brand new XR8 in the dealers yard and this too has the seam sealer in the engine bay, however underneath was as per the AU series 1. Already some rust is starting to form on this new ute underneath and also on the front of the engine bay near the bonet catch.
Seems like Ford may not of fixed this problem or they don't know the extent of the problem yet.
I even heard of one bloke taking delivery of a new XR sedan only to discover rust, so he took it back and demanded a new car. Apparenty he had the same problems with the replacement so he sold it and now drives a Holden and is happy as larry.
I'm starting to think the safest thing to do is to take my XR to the City and trade it in on a SS Commodore or something.
I know one guy in town is looking at taking the problem to "A Current Affair" as his is rusting and he has a heap of other problems with his XR6. This guy is a mechanic and has had Ford utes before, but is totally fed up with dealing with this problem.
He is basically giving Ford one last chance to fix it before he takes the drastic action. Judging by the list of faults he has including some pretty damning evidence I'd say ACA will snap at the chance to run a story on it.
I'm scared that such publicity would kill the resale of my XR8 so just another reason to maybe get rid of it before it becomes widely known.
Well, mate, I just recently had rust removed from my AU!!!
The sill below the doors, 2 major rust holes, and a couple of minor ones in the development stage!!! I do have a pic of it, but no scanner to load it up on here
I was very very shocked when I noticed them.
Wow, rust in an AU! I can't believe it. As far as I know my old mans AU is rust free, not that it matters since it will be an AUIII in the driveway before long. Heck even my EA only has minimal rust ie, little bit over the rear wheel arches. That is shocking... To quote Derryn Hinch "Shame Shame Shame"
:beerchuge 
A HUGE THANKYOU TO THOSE THAT ATTENDED THE 2004 FORD FORUMS CHRISTMAS CRUISE!!! 
IT WAS THE GRAND FINALE` OF VIC CRUISE EVENTS FOR 2004 - LOOK FORWARD TO CATCHING UP WITH YOU ALL IN THE NEW YEAR!!! 
CLICK 
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