2004 Chrysler Pacifica - 6 years old - 40, 000 miles, mint condition. Brought the vehicle in for its regularly scheduled oil change and the mechanic noticed that the subframe at the front right had rusted through (Chrysler had the car up for service in the spring to change the tires and did not notice anything). I was told that I can drive it for now but it probably won't be safe much longer. Brought it into Chrysler and they advised that its not covered by standard warranty, nor the extended 7 year bumper to bumper warranty that I purchased (expires next year), and that it will cost $3, 500 to repair.

Given that the car has been well maintained, and this is the only area under the car with significant rust (ex: I'm still on my original exhaust system and the car still looks new) I believe this is likely a manufacturing defect and should be covered by Chrysler. Has anyone had experience with this? Advice to share?