In many cases, there are no real or permanent cures for issues and problems caused or created by sloppy or careless assembly of your new car. If your two-week-old car ended up with sopping wet carpets after its first wash, your dealer might be able to reseal the windshield – but not always. Water and dust leaks are often incurable because they are caused by the way the car was built.
If you suspect your car is slightly out of shape and you are wondering why, here are some of the reasons:
Misaligned or Damaged Assembly Equipment
Modern assembly and construction processes are largely automated. Any defect or misalignment of equipment that holds body parts together prior to welding will result in a misshapen body shell. Since car bodies can be built at the rate of several hundred per 24-hour period on just one assembly line, it is impossible to check and if needed, repair assembly equipment on a regular basis. This type of problem is only detected during routine testing of sub-assemblies, by which time hundreds of misshapen body shells may have been produced.
Sloppy or Careless Fitment of Seals or Application of Underbody Sealant.
While door, hood, and trunk lid seals could be replaced relatively easily, proper reapplication of the underbody sealant requires the removal of everything that is attached to the underside of the car. This is possible on a few models but impractical in most instances.
Force Fitting of Doors or Body Panels
Perfectly good doors and other panels are frequently forced out of shape in order to get the fitment gaps right. While a door may seem to fit perfectly, with all the gaps the same width all around, a force-fitted door will invariably wear out its hinges prematurely or not allow the smooth operation of its window.
Improper Tightening of Bolts and Nuts or Other Fasteners
The over-tightening of a bolt or screw can be just as bad as under tightening. In many instances, the correct fitment and tightening of a single bolt is all that stands between a safe car and one that can cause a fatal accident (because that particular bolt had fallen out or snapped off because of the excessive movement of the parts it was supposed to hold in place). In many instances, a single bolt is all that holds the suspension, and thus a wheel, in position.
Improper or Inadequate Application of Rust Inhibitors
The improper application of or damage to the rust protection layer or coating on a body shell is virtually guaranteed to result in the formation of corrosion long before the corrosion warranty on your new car has expired – even if you do not live in a coastal area.
Sloppy or Inadequate Quality Control Measures
For various reasons, even obvious faults and defects on test vehicles may not be reported to the quality control departments of manufacturers. Since not every car is tested at every stage of assembly, several hundred defective cars may leave the factory before corrective action is taken.
Wiring that is mislaid or misrouted during the assembly process often leads to chafing or rubbing of the wiring harness. This defect often leads to major and sometimes fatal short circuits when grounded against the metal of the body shell or other grounded components.
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