Owner sues Alfa Romeo over rusting tailgate

The owner of an Alfa Romeo Tonale discovered rust on the rear doors after just one year, sparking a warranty battle with the seller, who claims that the problem is "completely normal."

An Alfa Romeo Tonale owner from Vancouver, Canada, reported a large rust patch and paint blisters on the rear doors of his vehicle after just one year of ownership. The problem, which is believed to be the result of poorly designed drains on the rear doors, has led to a dispute with the dealer. The owner noted on Reddit that Stellantis, the parent company of Alfa Romeo, is refusing to repair it under warranty, claiming that their rust warranty only covers “perforation,” meaning that the rust must be eating away at the metal.

In the photos shared by the owner, in addition to visible paint bubbles, small rust spots and peeling paint near the backup camera, tailgate lights, and door opener switch are also visible. While manufacturing defects are not uncommon in new vehicles, the seller's alleged denial of liability is questionable. No other Tonale owners in the Reddit thread have reported similar issues, suggesting that this may be an isolated manufacturing defect.

The assistant general manager of Alfa Romeo Vancouver reportedly dismissed the bubbly paint as “100 percent normal” and the same for all Tonale models, even offering a comparison photo. However, bubbly paint is often an indicator of rust or trapped moisture, raising questions about the quality of the paint job on the vehicle. The owner was also informed that the drain design, which has plastic plugs, requires more than 6 millimeters of water to collect before it can drain, which can exacerbate the rust problem.

Avoid the Tonale like the plague
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