They are still using wax coatings on frames. It’s all over the place on the web with people having one and two year old trucks with big areas on the frames peeling loose.
Here’s how hydro-formed frame rails are manufactured. It’s pretty clear that the hollow recesses the method produces could be an easy place for rusting to begin. I wonder if the manufacturer’s are making the mistake of focusing more on rust-preventing the outer surfaces than the inner?
I think there is def numerous factors. I think by hydro forming and boxing they can use thinner metal. Also, the GM wax coating is trash. Finally, I think the liquid brine road pretreatment (before snow) that is now commonplace is extremely corrosive.
I had the same problem on my 2005 Ford ranger. Frame rusted out, wouldn’t pass inspection next time. I had to get rid of it. There was no rust on the body panels and it ran fine. My 1995 s10, the frame is still rock solid, just surface rust. Both driven in the same northeast winters.
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