Exhaust Pipe Rust

[Tyler1986]

Hey Everyone,
My wife got her 2021 Bronco Sport in December 2021 and I noticed the other day that the exhaust pipe and exhaust tips are super rusty.

I first noticed rust spots on my garage floor so I peeked under the vehicle and saw the whole pipe is rusted.

I live in Canada and of course there are places I go where they salt the roads in winter but this Bronco has 8000km on it and shouldn't have rust on it.

Anyone else have this issue?

 

[Meanderthal]

That is pretty typical of an exhaust system. The heat seems to accelerate the process.

 

[Tyler1986]

That is pretty typical of an exhaust system. The heat seems to accelerate the process.

Oh really? Jeez that's a shame if it is. I agree that rust will eventually show up but I feel like its a bit early for the whole pipe to be looking like this. We've had a few new vehicles and neither have looked like this in the first 5 years of ownership. Thanks for the reply!

 

[Deleted member 6599]

POR-15 Stop Rust Kit - Gloss Black – Complete 3 - Step Rust Preventive System | Non-Porous Coating Seals & Protects Metal from Rust & Corrosion Permanently https://www.amazon.com/dp/B077J66P27/ref=cm_sw_r_cp_api_i_791CYHY1RHZJHX3FXS41

 

[Deleted member 6599]

Plus this for the exhaust…
Rust-Oleum Automotive 260771 11-Ounce 2000 Degrees High Heat Spray, Gloss Clear https://www.amazon.com/dp/B006ZLQ0JI/ref=cm_sw_r_cp_api_i_32VYGYGHFRH0SBMNBHQZ

 

[Meanderthal]

Oh really? Jeez that's a shame if it is. I agree that rust will eventually show up but I feel like its a bit early for the whole pipe to be looking like this. We've had a few new vehicles and neither have looked like this in the first 5 years of ownership. Thanks for the reply!

It doesn't look like Ford invested in having a stainless steel exhaust for the BS. It would appear that it is some kind of plain carbon steel with a coating to mitigate some of the rust. The tip looks so bad because the coating is applied to the raw material, so when the end is cut it is exposing the raw steel. Probably similar explanation for the other portions that are showing more rust, either they are close to a weld or part of a bend. Both of those things will break through the coating and expose the raw steel underneath. It is not a great sign for exhaust longevity, so I would keep an eye on it and maybe prepare for a fully rusted out exhaust in 4-5 years based on what you showed.

 

[Mark S.]

It doesn't look like Ford invested in having a stainless steel exhaust for the BS. It would appear that it is some kind of plain carbon steel with a coating to mitigate some of the rust. The tip looks so bad because the coating is applied to the raw material, so when the end is cut it is exposing the raw steel. Probably similar explanation for the other portions that are showing more rust, either they are close to a weld or part of a bend. Both of those things will break through the coating and expose the raw steel underneath. It is not a great sign for exhaust longevity, so I would keep an eye on it and maybe prepare for a fully rusted out exhaust in 4-5 years based on what you showed.

I'd be surprised if it's plain carbon steel. Aluminized steel seems more likely. Cheaper than stainless, but not as corrosion resistant.

 

[Meanderthal]

Aluminized Steel is an aluminum coating on steel. That pretty much is inline with what I explained.

 

[Escape2Bronco]

Well, that will be a bummer. I’ve gotten used to not replacing exhaust systems. Back in the day, it was a yearly event. Most of the muffler shops changed business models. Midas, Mienike, and others only did mufflers at first.

 

[MJE]

Well, that will be a bummer. I’ve gotten used to not replacing exhaust systems. Back in the day, it was a yearly event. Most of the muffler shops changed business models. Midas, Mienike, and others only did mufflers at first.

I’d almost forgotten that used to be a thing. Replacing your exhaust was pretty much a maintenance item.

 

[Bdud]

And I thought it was bad that peoples roof rails bolts were rusting on a 30k vehicle.

This vehicle is something else. I've been trying to find a Maverick so I can get rid of this thing but now I'm wondering what else ford skipped out on to get the price point of the maverick that low.

 

[LilbroncoS]

That is pretty typical of an exhaust system. The heat seems to accelerate the process.

Typical on a 10 year old car maybe

 

[LilbroncoS]

Ill paint mine with a heat resistant black that protects against corosion.

 

[Mark S.]

Aluminized Steel is an aluminum coating on steel. That pretty much is inline with what I explained.

You're right; I missed the "with a coating" part!

 

[Major Kong]

Just starting to research Exhaust Hi-Temp Ceramic Coatings
Paint coatings for aluminized steel info not readily available or so it would seem

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