2009 Rear End Rusting Issue - Is This A Problem?!?

ttucker512 · October 23, 2009

My almost brand new 2009 has barely 7k miles on it and has been garaged kept day and night since day 1. After my first drive in real rain here in Colorado, I look at my rear end and notice a huge red spot where paint has flaked off the differential housing. Upon further inspection I find all the paint on the housing is about to come off as well as section of the underside and front. Should I be concerned? My first thought was maybe low fluid or some reason it was running hot that would cause premature paint failure. After a 30 minute drive on the highway it was slightly warm to the touch but nothing unusual. I also have an 08 Sierra with no such issue. I have NEVER heard of a rusting differential housing on a truck this new. Makes me worried about later on down the road. Should I call the dealer or just spray some WD40 and forget about it??

What do you guys think?

pm26 · October 23, 2009

Not a big deal. The rear differential cover is made of stamped sheet metal. Surface rust will not hurt it, but you should take care of it. If I were you , I would scrape off the loose paint, sand down the cover, prime with black high temperature engine primer, and then top of with black high temp engine enamel paint.

Or, if you wish, you can take it to a dealer and request that they replace the cover. Which of course means a new gasket and changing the rear end oil too. Or, they may elect to refinish it.

ShoddyHog · October 23, 2009

Rust?

No comment

Gerry

MS3DALE · October 23, 2009

Rust?

No comment

Gerry

Ahh C'mon Gerry

ttucker512 · October 23, 2009

Thanks for the responses guys. I'm probably over-reacting. Just hate the way that looks on a brand new truck. Will probably just sand and paint...call it taken care of

RJG183SA · October 23, 2009

Judging by the photo, it appears that the paint might have been applied over the rust.

The way it is cracking looks like poor adhesion.

ShoddyHog · October 23, 2009

Rust?

No comment

Gerry

Ahh C'mon Gerry

I know NUH THING!

Tsmith · October 23, 2009

Mine looked kinda bad too. Just roughed it up with some sandpaper, masked off the area and sprayed it black. Also did the rear brake drums at the same time.

pm26 · October 23, 2009

Some ten years ago i saw a brand new GMC truck on a dealer's lot and the entire chassis, including the rear axle housing, springs, frame, etc. had surface rust on it, it looked like it was submerged in water for a week. It was a bit too much for a new vehicle.

ShoddyHog · October 24, 2009

Some ten years ago i saw a brand new GMC truck on a dealer's lot and the entire chassis, including the rear axle housing, springs, frame, etc. had surface rust on it, it looked like it was submerged in water for a week. It was a bit too much for a new vehicle.

lol

Must resist temptation...

weagle99 · October 24, 2009

When you really examine these trucks and identify some of the areas where GM cut costs it is a little discouraging. Don't get me wrong, I really like my '09, but to be honest my old '02 seemed to be of higher quality in a few ways. For instance, you can look at how the new trucks are assembled and see the changes GM made to allow for looser (cheaper) tolerances.

A rusting diff cover is obviously under the truck and not easily in view, however who among us wants to see something like that so soon on a $40K+ vehicle? To be honest it makes me wonder how the vehicle will hold up over the long haul...

Starrman · October 24, 2009

My '01 doesn't even look like that

2005LT · October 24, 2009

My '01 doesn't even look like that

Yeah, my dad's 03' Sierra doesn't have any rust on it, or at least nothing like that. I'll be keeping watch on my 09' but so far so good.

dlstewart01 · October 24, 2009

Guys...they have been like that as long as I have been buying trucks, and I go back quite a ways. Can't say I ever gave Henry Ford advice but I was born before he died. Most people don't pay it any attention. It will not rust through. Those of us who are anal just sand it off and repaint it (have done this a few times) or put an aluminum cover on. Have done this a bunch of times.

I pulled the one on my 05 off when it was about 6 months old, completely rusted, and put on a mag-Hytec. Have never looked back.

You got to deal in reality not what you think it ought to be.........

Irv · October 24, 2009

Should I call the dealer or just spray some WD40 and forget about it??

What do you guys think?

WD-40 is crap, use a penetrating oil or something similar that has silicone in it, WD-40 will not last especially in that location.

Personally I would sand and repaint and once dried/cured for a few days spray some Rust Check or Krown rustproofing on it? If it is available in your area I would get the whole truck done too! I have noticed on these newer models, rust starts way too early compared with trucks less than 10 years ago!