2 larges patches of rust have appeared, one at each side of the car, inside the door frame and underneath the heavy rubber seal which runs around the door frame. The patches are completely symmetrical and have formed around a seam (join) in the metal of the door frame at each side of the car.
Ford UK say that this is not covered by the 6 year rust warranty and are refusing to accept responsibility for what would seem to be a manufacturing fault...
This car has been kept in a garage when not in use and has been cared for in accordance with the manufacturer's instructions. It is (apart from the rust) in excellent condition.
Would you buy another car from this manufacturer? Don't Know
Review Date: 23rd October, 2000
7th Apr 2005, 13:57
I have had the same problem.
I have a millennium (yellow) ford KA, and it has rust in the same places as described above. On the door frame, in the bottom corner.
I took it to a Ford garage today, where they've taken photos, and I am now waiting to hear back.
Apart from that, its been a very good, reliable car.
8th Aug 2009, 11:24
I have a W reg KA bought eighteen months ago by private sale. It has cost me almost as much as I paid for it to get it through two M.O.T's; all to do with rust. I tend to look closely at other KA's and most of them seem to have rust round the petrol cap. Mine is also on the door casing (sorry female description) and underneath. The mechanic described KA's as disposable cars! Unlike my income.
26th Oct 2009, 11:47
Our 53 plate KA has just cost us £200 to have the rust around the petrol cap made good, all the rest of the bodywork is in good condition. Garage said it was a common fault, so why haven't Ford done something about it and paid for the repairs, I have since seen many other KA's around with same problem, maybe we need Anne Robinson on the case!
27th Oct 2009, 02:28
This is a very common fault on the Ka, along with underside surface rust.
The fuel filler area was not coated well enough on the inside on the production line and is badly affected by condensation.
Thing is - you could buy the base Ka for £4995 new in 2003, and 6 years use for around £800 per year is cheap, even if you had to throw it away now.
If you have a Ka not affected yet by this rust, it would be wise to gain access inside the panel, dry the area out, apply Kurust, then waxoyl when dry.
The Ka is known for rust issues, but is a very cheap and fun car. You can't expect recall after 6 years for a non-structural rust issue.
Average review marks: 6.5 / 10, based on 16 reviews