Mine has it too, pretty annoying. Worst on the side where I actually open the close the door alot. Completely unacceptable, but I have hopes it won't get worse.

 

I took my new '04 SCAB (2,200 miles) to a local Ford dealer to fix the wavy sheet metal below the window of the driver’s side back door. I gave them the TSB number; they had never heard of it, so I was a bit skeptical to begin with. Anyhow, this Ford dealership had a body shop, so I had some hope. Low and behold, they had my truck for three days. They gave me some excuses; said they had to order another kit because there were two patches needed for each door (there’s only one patch in a kit).

Well, they did not fix it, nor did they paint it (thank God!). They said they had to put two kits on each door (I at first thought this was B.$.).



When I got home, I pulled the inside rear door panel off to see what they did or did not do. What they did not do is remove the old material!!! (It is extremely hard and difficult to remove). Then they installed the new Mastic Patches right over the old factory patches. One patch (driver’s side) had broken loose and fallen or had been peeled off (that is where the wavy area is located). They didn’t even remove the pieces that had fallen down into the door bottom (this might be a cause of a “rattling noise”). They also put a new patch at the bottom of each door, over the factory mastic. At least they did not spray the anti-corrosion right over the old material. There were no waves on the passenger side.

I called back to the body shop manager to explain. I was careful not to tick him off. I told him everything; but he played dumb. However, he did agree to order me two more kits and just give them to me. I picked them up yesterday, one patch per kit, not two, free of charge.

You will need a small trouble light to look for the factory mastic patches (6" X 13"). I suspect the factory mastic was an early fix, and some were improperly applied, and later the cause of the waves after falling off due to cold weather. I think it turned out to be a botched solution on early production vehicles. I have seen reports of wavy areas at the bottom of doors; that explains the bottom patches. If you have the factory mastic, they (your dealer) or you (at your own risk) will need to carefully remove it as described in the TSB. If you do not have the factory mastic, the TSB kit will probably fix it, I’m not sure. Just by removing the factory mastic made the wavy condition disappear! I didn’t need the kit, but I did put it on after removing the factory material. It took me around three hours of carefully heating and scraping (and other things). I was scarred I would make it worse, but my door is now perfect!

I am curious to know what others find. Also, I’m curious as to what’s inside the doors of trucks built after 11/12/2003.


If you had an experience with this TSB, good or bad, please post. THANKS!

 

Can someone who has the wavy doors post a before and after picture. I'm curious as to what this condition looks like.

 

I just looked at mine, this is what I have:

Build Date: 08/03 Norfolk, VA
Purchase Date: 01/04
Miles: 10,612

No wavy door panels.

 

So, what is the actual tsb #?

 

I'd like to see what this looks like also if anyone's got pics.

 

Here's what to look out for: wavey rear scab doors....






JUST KIDDING!!!!!

 

Won't be so funny when your doors start denting, and they will.

 

can someone post a picture of the actual waves?

 

BlackLariat,

Wish I could. I had a Aspen green SuperCab but I traded it on a new SuperCrew. I loved my supercab but the dealership was playing dumb about the problem and I refused to have a new truck with bondo and aftermarket paint. My dents were obvious. Vertical lines running parallel on the doors. If you can't see anything when you look down the side then you don't have them. You might want to read some of these posts because someone mentioned that it is the sound damping material on the inside of the truck. If it is removed and replaced then you should be fine. Anyway, sorry for not taking any pictures.. Still a little mad about the whole thing.

 

Sorry I can't post a picture. The dealer has had my truck for 2 weeks. But like the previous post said, if you look down the side of your truck and don't see anything obvious you don't have it. I literally could see the ripples from thirty feet when approaching my truck from the rear at an angle, like when walking out of a grocery store or bar.
By the way the picturre above with the wavy doors is pretty funny.

 

My Scab is in the shop as we speak for this problem. The dealer ordered new panels and is going to put those on. I am leery that they just Bondoed my old doors and are repainting them. I put a call in to my service advisor to hold the old doors til I pick up the truck so as I can inspect the color match of my new panels. Heaven help those guys if it isn't a spot on match!

This has taken longer than I'd have liked, but I do hope it turns out okay. I gave my SA the TSB for the problem, and I THOUGHT he was going by that. That is why the "new panel" bit is scaring me. Just have to wait and see til Monday!

-Travis

 

I got my truck back today. The dealer had it for three weeks. Doors look good as new. The dealer followed the TSB and removed the mastic and replaced. They did not sand the doors down and repaint. I can tell because I had a couple of small scratches that are still there.
It was frustrating that the process took so long but the results are good.
Best of luck with your truck.

 

After reading this i had to go look, build date 7/03 no ripple.

 

My Lariat Scab has few of these vertical ripples under the rear windows.. Unless you are really looking for them they are tough to see.

My question is being that the truck is leased I'm thinking I should let the dealer look at it and give me written statement about this condition.. Like I said they are not that noticeable and I don't care if they fix it or not, but I don't want them coming back at me at the end of the lease because the rear doors are rippled...