Severe Rust on new Jayco

[ClassCrunner]

[FONT=&quot]I would like some opinions on what I should do about my new Jayco. This is my problem: Last Feb. I purchased a new 2023 Jayco Redhawk 24B from an out of town dealer. The promised delivery date was pushed back because as I was told: the power converter is not working properly and that they would replace it. I drove the 890 miles to the dealer and arrived as they were installing a new converter. We did the paperwork while it was still being worked on as I wanted to start back home asap. To my dismay, the new power converter refused to charge the batteries. The dealer was nice enough to let me spend the night in the RV plugged in to his shop. [/FONT]
[FONT=&quot]The next morning the service tech was working under the RV and I heard him drilling into the frame. He came out and told me that the problem was just a faulty ground for the converter and it is now working. He never mentioned anything about rust. I made sure that everything was working and left for home that afternoon. The next day as I stopped to use the microwave; the generator quit working and would not restart. [/FONT]
[FONT=&quot]A day or two after I arrived home I started to check out the generator and found that the positive battery cable to the starter solenoid was loose because the nut was cross-threaded and wouldn't tighten. As I was checking it; I noticed a lot of rust under the generator and the more I looked the more rust I found. I found the faulty ground had not worked because the bolt holding the wires to the frame was so badly rusted that it is now broken off and the star washer is rusted into the frame. The service tech had moved all of the wires inches away and used self-tapping bolts that barely missed going into the fuel line. [/FONT]
[FONT=&quot]This RV has a severely rusted driveshaft; heavy rust on the hydraulic pump and hose fittings for the leveling jacks; the step motor, the hydraulic brake lines, rear springs, front spindles, parking brake cables, frame rails, storage compartments, etc.[/FONT]
[FONT=&quot]I have gotten no help from Jayco other than to tell me that the warranty does not cover rust and corrosion and it is the dealers problem. The dealer keeps telling me that Jayco is responsible. [/FONT]
[FONT=&quot]Finally, I was told by the new general manager of the dealership back on June 28 that Jayco was working on a plan to pick up my RV and bring it back to the factory for repairs. Over 3 weeks later I was told that Jayco can’t do anything until at least November. None of the in state dealers will repair the RV but I did find an independent that gave me an estimate based solely on pictures for $5,200.00. The dealership GM told me to take it there and he and Jayco would reimburse me for the repairs. However, upon viewing the RV in person the owner of the company declined to do the repairs. I haven’t been able to find another shop. On 07/25/24 I told the GM that either Jayco does the repairs sooner or he gives me a refund or another unit. I did get a call from the Jayco factory rep. on 08/09/2024 and he seemed to want to help; however, after a week or so, I was told that Jayco would not cover the cost of picking up the unit. I agreed to drive up to the factory, about 1,100 miles, I was told in mid August that the warranty manager will call with a schedule. As of today, 08/27, I haven’t gotten a call. I sent a text to the rep. last Thursday for an update and haven’t heard back yet. [/FONT]
[FONT=&quot]Has anyone else had this problem? The rust appears to be caused by road salt never being removed after delivery and then sitting in an area with high humidity. [/FONT]
[FONT=&quot]I now have a very rusted new RV that I am reluctant to use and neither the dealer or Jayco has done anything about it. It has a new vehicle warranty but anything damaged by rust is not covered either by Jayco or Ford. In Texas by law; once you drive a new vehicle off of the dealers lot; you have little or no recourse for something like this. Beware before you buy. I never thought that I should have crawled under a NEW RV before buying it. [/FONT]
[FONT=&quot]Early on I had a very reputable RV company send out a tech to inspect it. A portion of the report is attached. It is lengthy but if you read the last few lines you will see where the tech thought that this should have been sold as a used vehicle. [/FONT]
[FONT=&quot]The dealer that I purchased it from is: Gregg Orr Marine and RV in Texarkana, TX. [/FONT]

 

[Grumpy]

It is probably from road salt and weather exposure from when delivered to the dealer and really not an issue.

As to you what you are experiencing from the local dealer, that is not unusual since they are independent. Jayco has always said "by local"..

Couple other discussions...even on the Super "C"'s

https://www.jaycoowners.com/forums/f64/seneca-s2rv-corrosion-80346.html

https://www.jaycoowners.com/forums/f5/surface-rust-in-various-chassis-area-84340.html

 

[ClassCrunner]

Grumpy,
Thanks for the reply. It is a big issue. It is badly rusted in spots. So bad that it rusted off the main 12V grounds. The dealer had to replace it before I could drive it away. He neglected to mention just how bad it was or anything about rust. Jayco has been absolutely no help at all. I drove almost 900 miles to purchase a new one with the factory warranty and I am being told by Jayco that their warranty does not cover rust even though it was sold to me in that condition.

 

[pauldeere]

I know this is no consolation to you but as mentioned in the previous reply the rust could have come from road salt on your RV's delivery from Indiana during the winter months. Road salt, or calcium chloride which are both used on roadways in the winter months are the single most damaging chemicals you can expose your vehicle to. It would not surprise me that this was the reason for the rust on your RV.

 

[Jump in say hey]

rust

Sorry to hear of your situation. so now what do you do. You'll see numerous You Tube post on addressing rust. Our unit was a bankruptcyfrom eastern South Dakota, but fortunately not quiet that bad. Rustoleum rust renovator is just a basic approach. NAPA has a product called Rust Shield. It's a two part mixture. It will burn your skin, and wears off in two weeks, use gloves. However you still will need to use a wire brush on a grinder aggressively, or mild sand blast first.. Rustoleum also has a cold galvanizing paint that has its place.

Make sure you use deoxy on electrical contacts. Better yet use a product called Whip on all electrical connections and batteries, it will penetrate thru corrosion and prevent corrosion. Best wishes, its a long process.

 

[Grumpy]

Grumpy,
Thanks for the reply. It is a big issue. It is badly rusted in spots. So bad that it rusted off the main 12V grounds. The dealer had to replace it before I could drive it away. He neglected to mention just how bad it was or anything about rust. Jayco has been absolutely no help at all. I drove almost 900 miles to purchase a new one with the factory warranty and I am being told by Jayco that their warranty does not cover rust even though it was sold to me in that condition.

Taking a closer look at the ground issue, that bolt was over torqued and snapped off, not rusted off. I can't address the repair as I can't see the other side. I think your complaints are primarily with the dealer and not JAYCO. They should have done a better job of preparing the rig for sale.

You also have to remember the chassis sit out in the weather before the house is even built and as you can see, rust on the drive shaft is there from the beginning. Straight from FORD and not a big deal.

 

[ClassCrunner]

Grumpy, I believe the bolt snapped off when the tech tried to take it loose. The ground did not have continuity because of the rust. You can see the star washer in the picture rusted to the frame. There are other grounds that do not have continuity as well.

As for the driveshaft; Jayco balances them and paints them on the E-450's. Almost all of the paint has turned to rust. There are bolts so rusty in the front and rear suspension that it may not be possible to remove them if work is needed.

Jayco delivered this vehicle after it was driven in the snow and most likely picked up the road salt. Did they inform the dealer about it? I know the dealer is responsible because they sold it to me but Jayco has not helped one bit with this problem. I had a similar problem with a Winnebago dealer and one call to the factory got the dealer to take care of a $10,000.00 repair.

 

[dwaynebmsg]

Here's my nickels worth, (inflation), I would hold the dealer accountable, up to suing if necessary. You bought it from the dealer, not Jayco. It is the dealer's responsibility to deliver an acceptable product. Sue the dealer for your money back or repair cost. It is a dealer/manufacturer problem, not a customer/manufacturer problem.

 

[ClassCrunner]

Dwaynebmsg, You are correct that I should sue the dealer, but I have consulted a couple of attorneys and both said they would go after the dealer and Jayco. It is $5K up front and another $50 -75K if it goes to court. I am 79 and I do not wish to spend the next couple of years in a court room especially 900 miles from home. I have been hoping for the last 6 months to get the dealer and/or Jayco to take care of it but so far just promises. It would appear that Jayco delivered it to the dealer contaminated with the road salt. I still have the option to sue.

 

[Grumpy]

It would appear that Jayco delivered it to the dealer contaminated with the road salt.

A third party delivery company delivered it. Jayco does not know what the road conditions were.

 

[ClassCrunner]

Grumpy,
The attorneys that I have spoken to seem to think that Jayco does have some responsibly as they hired the transport and until it got to the dealer, it was still their unit. I am sure that if this went to court the responsibly for each party would be worked out.

 

[Grumpy]

Grumpy,
The attorneys that I have spoken to seem to think that Jayco does have some responsibly as they hired the transport and until it got to the dealer, it was still their unit. I am sure that if this went to court the responsibly for each party would be worked out.

No. Nothing leaves the factory until Jayco has a check in hand from the dealer. Been that way for as long as I can remember. They emphasis that if you take the factory tour.

It then goes to the shipping company and it could sit for a day, a week or longer until they find a driver going in the right directon. Last time I was there the lot had multiple brands sitting there.

 

[norty1]

I have had good luck killing rust with a product called POR15. Paint on Rust. It's gone and does not come back. Available as liquid or spray.

 

[Rock-JAY]

Your first mistake was not spending a full day doing a PDI or you would have found this. My dealer I bought from Is 4 hours away. I spent a day doing a PDI and there tech fixed what I found. When I found water and staining under the cab mattress I cxd the deal. I than ordered a new 24 30Z which took 10 weeks. Also spent a full day doing a PDI and took delivery.

 

[pconroy]

Dwaynebmsg, You are correct that I should sue the dealer, but I have consulted a couple of attorneys and both said they would go after the dealer and Jayco. It is $5K up front and another $50 -75K if it goes to court. I am 79 and I do not wish to spend the next couple of years in a court room especially 900 miles from home. I have been hoping for the last 6 months to get the dealer and/or Jayco to take care of it but so far just promises. It would appear that Jayco delivered it to the dealer contaminated with the road salt. I still have the option to sue.

Look, I'm sorry about the rust, but I think suing is not going to work out. Jayco is owned by an extremely large corporation with a legal team likely the size of a small army.

You'd be in court - or more likely arbitration - IN INDIANA. And it would take years.

At 79 , you're not that far in front of me.
We know -- stuff rusts.
It's not if, but when.

I'd stay on working the DEALER to get the rust removed, but that's with you picking a half-dozen of the worst spots. Work together, ignore the surface rust and together pick out a few of the spots that really concern you about structural issues.

Camp out in their parking lot. Write emails daily. Call hourly.

 

[ClassCrunner]

Rock, I did what I thought that a brand new RV would need. I checked everything on the inside and outside. I made sure that everything worked. The one thing I didn't check was to crawl under and inspect the underside. My mistake. I had confidence that since this was a new vehicle with only 900 miles and had both a full warranty from Jayco and also Ford; what could go wrong?
My biggest disappointment is the lack of concern from Jayco. A Jayco dealer sells you a new Jayco that is not just surface rust but enough to damage ground wires so that the dealer had to replace the ends and all that they can say is "Our warranty does not cover rust". Two weeks ago the factory rep told me that he would work to get it picked up and brought back to the factory and then later, there would be no pick up, I would have to deliver it. He promised me that Mike at the factory would call to schedule when to bring it in. My phone has not rung and the factory rep has not answered my last text from over 10 days ago. This has been going on for over 6 months.

 

[ClassCrunner]

Pconroy, Thanks for the advice. a law suit would be a last resort but I have that option for another 6 months. I am trying to work it out with the dealer and Jayco. They keep making promises but nothing happens. I would visit the dealer but he is 900 miles away.

I have a lot of concerns about the future of this unit. Can the rusted nuts and bolts in the suspension be removed if some future work requires removal. With the rust and corrosion on the wiring, pump and motor of the hydraulic jacks; will it fail? The step motor is the same. There is a ground on the fuel filler neck that does not have continuity; is that safe? How far has the rust penetrated the hydraulic brake lines; will they leak? BTW, did you read the report that I got received from a major RV dealership? Just read the last few lines.

 

[Grumpy]

You'd be- or more likely arbitration - IN INDIANA.

Yep, they already have a dispute program that's even free.

https://www.demarsassociates.com/rv-warranty-dispute-program

 

[pconroy]

Can the rusted nuts and bolts in the suspension be removed if some future work requires removal.

Colorado uses Mag Chloride which will rust you out faster than anything.

I grew up in Wisconsin. In the 60's - 80's. More salt on the roads that on French Fries. Yeah, the nuts and bolts can be removed.

I understand your frustration.

 

[Rock-JAY]

Rock, I did what I thought that a brand new RV would need. I checked everything on the inside and outside. I made sure that everything worked. The one thing I didn't check was to crawl under and inspect the underside. My mistake. I had confidence that since this was a new vehicle with only 900 miles and had both a full warranty from Jayco and also Ford; what could go wrong?
My biggest disappointment is the lack of concern from Jayco. A Jayco dealer sells you a new Jayco that is not just surface rust but enough to damage ground wires so that the dealer had to replace the ends and all that they can say is "Our warranty does not cover rust". Two weeks ago the factory rep told me that he would work to get it picked up and brought back to the factory and then later, there would be no pick up, I would have to deliver it. He promised me that Mike at the factory would call to schedule when to bring it in. My phone has not rung and the factory rep has not answered my last text from over 10 days ago. This has been going on for over 6 months.

I went through what u are but not rust ( gen, suspension rubs, roof and slide issue on my FW. I had to take it to the factory and they had it 2 months. Cost me several K in travel. The first motorhome I CX it was a 2024 but the Ford was a 2023. U might also have a year older Ford frame that sat rusting in the storage yard for awhile. My now 2024 is a 2024 built Ford. And yes that rust sucks.