I have noticed a few months ago paint blisters located at on the passager rear lower corner. So I have started to take notice of other f150 of the approx same age and have notice alot have this same problem. There is no blistering or rust anywhere else on the truck execpt for the same location. So obviously there must be a problem with water getting inside the cab corner somehow.
I have gone to a ford dealer (Best Ford of Nashua) and was told that this is not a warranty fix, its just the age of thruck and in the New England area it is expected to see this type of thing.

Help....is the dealership blowing smoke?

-Phil

 

it's a 8 year old truck and your probably driving on salted roads in the winter...it's gonna happen...not much you can do about except try to keep the truck as salt free as possible...wash it everytime you get a chance during the winter months...

 

And wax every painted surface, and even your frame. My previous '04 looked fantastic after 4yrs of salty P.A. winters.

 

It's from the salt and you not spending hours laying under it with a hose. This why "winter beaters" were invented.

 

Possibly water leaking in the 3rd brake light and rotting it out?

 

I know where your talking about on the cab. I'm dreading even thinking of this myself.

 

I have it on both corners of my 04 S-Crew, but I live in the "Salt Belt" of Ontario. I also have it on the rocker panels. I am getting them changed on both sides this month and having all of the Grey on the bottom repainted, as well as the bumpers. It'll be close to $2000 worth of work... The actual cost of the corners and rockers were minimal. My friend owns a body shop and he showed me his List Price on the parts... I want to say around 80 for the cab corners, and 110 for the rockers or vice versa...

 

I have had this issue for quite some time now but have put off fixing it. I scoped it out and followed the inside seam where the inner and outer panels of the cab meet. If you follow it up, there is an opening about half an inch wide that leads to the area. Does anyone know if this is the cause of the rust? I am going to plan on closing off that opening in hopes it will help solve the issue.

Going to stick my borescope down that opening and into the corner to see what I can find.

 

http://www.fixmyrust.com/2004-2008-f...crew--AHK.html

Then oil the **** out of it...

 

How does one check for this? Please advise.

Thanks!

 

I have pretty bad bed rot on my 04 Screw. Trying to figure out which way yo go to fix it because the outer body of the bed is mint... Also Im thinking about the cab corners... The ends of them have some spots on them so before the inner cab corners start rusting out im going to grind what i can out of it and POR-15 the living s#1T out of it. hopefully then I will get a few more years out of them...

 

Windsor is the Salt bed of Ontario! Mine took a beating this winter. Time for some body shop love soon!

 

Found this helpful article on how to prevent and protect your car from road salt:

http://www.dmv.org/how-to-guides/road-salt.php