I washed my truck over the weekend, and gave it the full on detail. I discovered a number of rust issues that my dealer has confirmed that I am the 5th customer to report the issue at their service dept.


The bottom of ALL 4 doors, along the inside lip are beginning the bubbling process of corrosion beginning. I ran a plastic scraper down it, and chipped the head of the blisters off before I took it to my dealer. The doors have to be clean to see it, as the slightest dirt will mask it pretty well. I remember in the late 90's and early '00's the F150's did the exact same thing.

You have to look closely in the pic, but you can see the bubbles right along the bottom of the lip, just before the fold intersects the inner panel. It is like this along the whole bottom of all the doors.



My front bumper is also corroding. I might have a problem trying to get Ford to cover it, but I am willing to fight to the death on this one. There are several chips, (20,000 miles worth) on the front steel face bar, but even in places where there are no chips the bumper is showing that slight wrinkling rust look. I took pics, but the rust doesn't show up at all in them. You have to look closely, and the cam can't catch it in the darkness right now.

All 4 of my rubber door seals are rusting at the bottom where they join too. Spread the crack open and have a look.

FYI, have a look at the inside edge of your doors.

Dealer took pics, and sent the repair request to Ford Canada...... We will see........ I will advise y'all what I learn.

 

Man that sucks, i just went and look at my 05 lol. When i lived back in Michigan i saw several NBS chebbies that had the box rusting away above the rear fenders. Maybe you can line-x this after Ford repairs it?

 

That's brutal man....keep us up to date on how Ford deals with this.

 

My bodyshop friend advised me to spray some light oil into all my doors so it would work it's way into that seam area and help prevent the rust from starting there. He says it happens alot on the newer cars. Granted, I do live in one of the worst "rust belt" states and they now use a salt brine every storm to prevent icing. That along with the pea sized gravel they totally cover the road with and call anti skid, your vehicle takes one hell of a beating around here. It will be interesting to see what they tell you.

 

Your friend is right. However, I am a licensed journeyman bodyman myself, and took the doors apart on the very day I brought the truck home in early 2010 and sprayed all the doors with an industrial wax oil. It is a state of the art product not available to the general public, and is designed exactly for this purpose.

So much for that idea huh? It should be mentioned that I don't live in a particularly salty part of the country, and there is a very low rust problem in my neck of the woods. I do however park the truck in a heated garage at home, but it sits in the sub zero temps while I am at work. This might be a metal condensation issue, and that is where my money would sit if I was a betting man.

I should hear from Ford within a week.

 

Well, crap man! That sucks! Definitely keep us posted as you hear more. Hoping fer the best!

 

Damn. I will be keeping a close eye on my 2011.

My 02 didn't start showing that door rust until it was eightish years old. That was with no special treatment other than an occasional wash and even more occasional wax. The tailgate started much sooner and was shot when I traded. The doors were still solid and looked perfect from the outside.

The rockers from the inside out was its death blow and the reason I traded it.

This is in NW Vermont where the salt is used heavily.

Please keep us posted.

 

The inner panel that is introduced into the outer panel's lip on my '10 Scab's passenger door has a series of paint bubbles, just above my outer panel's turned-up lip.

I scraped it a little and no bubbles broke so I don't think rust has invaded, yet.

My driver door is fine and the rear doors of the Scab are fashioned differently from the full sized doors and they are fine, also.

I do live in a real salty enviorment in the winter, too. They 'pre-salt' the roads with a brine solution here when snow is just in the forecast. Wotta waste.

My truck has never seen the inside of my garage.

 

After ford fixes it and even if they don't take it to Krown asap. If you keep up with it every year it works pretty good. My parents have an avalanche and they did it every year since new (03) and it always looked great. they stopped a year or 2 ago and just now is it showing rust but it looks better then some 06's and even an 08 i compared it too.

When it goes directly over rust it seems to not last as long- I'm still experimenting with it on a freshly tremcladed undercarriage to see if it works better.

there might be alternatives in your area that spray a different oil on it but I don't have much experience with them. but they seem to work almost as good.

I do not work for Krown or even endorse them that much. but for newer vehicles definitely worth it imo.

(note: we live where they use that brine stuff and also salt on some roads sometimes)

 

Winter beaters, the only way to have a rust free truck.

 

I know a few owners of commercial large trucks and they spray the whole underside with soy oil once a year ! Works well and the oil is cheap.

 

WD40 worked well for me in the past. You need something light enough to penetrate the seam. Then I followed up with a block of wax and sealed up the seam with wax. Only did it once when truck was new, but didn't have issues in the 5 years I owned it. I'll do the same with my 2012 in October.

-Andy

 

Viscotine the crevices and fluid film the entire underneath

 

Lol! I have had an old Chevy 4x4 I use for plowing for years. I just licensed and insured it for winter driving yesterday. It was after reading this thread about rust that I decided to get it ready for the road. Can't beat a winter beater! Hope I don't have to go too far as top speed is about 55 mph! Wife yelled at me she isn't gonna ride in that thing! Hahahahah.......

 

While I hate living in an area where 100+ temps are normal .. not having to deal with salt on the roads is a big plus. Left the NE in 2003 after 14 years, and we are never, ever going back ..



I am interested to see how Ford deals with this.