I think I read this before awhile back - about rust on the lower inside seam of the doors. I noticed a little bubbling and took it to the Dealer. They say it's common and are taking care of it as I speak - no hassles. I wanted to get it before it got any worse.

Check your doors! (Front and Back)

 

I'm picking up my truck today. Had all 4 doors repaired as well as the tailgate. No hassle under warrenty. I've got about 600 miles left.
Here's what it looked like before:

Driver Door


Passenger Door

I'll try to post some after pictures when I can.

Tom

 

Sad to say but I think I have a few bubbles myself.

 

OK. Got my truck back. Here's a few "After" shots:


Driver Door



Passenger Door


Passenger rear door

Other pictures can be seen in my Gallery: https://www.f150online.com/galleries...w.cfm?num=3630

Good luck to all that may have this condition.

Tom

 

Go and get a rust proofing place to hit the doors, the rear tailgate and the insides of the chrome bumpers.

This is an old problem dating back to the '97 models. I've had every truck since then rust proofed. No more problems in those hot areas.

 

Hey Dennis...

What does a rust-proof job run price wise?

RP

 

I honestly don't know. I make the dealer do it as part of the deal. Same with the drop in liner and the third PATS key.

I think they normally charge about $500 to rust proof. The stuff looks like bee's wax.

When I turned in my '97 for the '99, I made them rust proof the '99 truck because of the problems that people were having with rust here on this board. The hot spots were the bottom of the tailgate, the bottom of the doors, and the insides of the bumpers.

 

Thanks Dennis...

After I raise a little kane about the door rust thing, I might shell out the dollars for the rust proofing... kinda sad to think that a 2 year old already has rust.

 

I don't know why this kind of stuff is still happening. It's the only place that ever rusts. I thought they're using galvanized steel, but for some reason these areas seem to defy science. All I can figure is the water must run down the inside of the door and settle in the seam. The rustproofing stuff fills the seam so water doesn't get into it. If that's the case, I wouldn't do the rustproofing too soon after washing the truck or driving in rain.

Has anybody seen a rusted out '97 or newer truck? I sure haven't. Yet, the bottom of the doors all get rust in the same somewhat hidden spots.

You'd think Ford would have fixed this problem. It's been around since the '97 model run.

If you only get the hotspots hit with the rust proof stuff, it shouldn't cost much. Probably take them all of an hour to do it to a SuperCrew and still have time for a cup of coffee.

Seems stupid to have to do this, but since I've been having it done, I don't have any problems in the area. You should know that if anybody is going to have rust, it's me. My truck sits outside and gets hit with salt laden air practically 24 hours a day. When the ocean is rough, you can actually see the haze from the salt.

 

Yeah, I must agree.

I'm going to have the warranty deal with it this time but, I am planning on keeping this truck for quite a while (potentially for a lifetime) and, I need to nip this in the bud right now.

It is totally ridiculous that we're having to deal with an issue like this on a 2-3 year old truck.

RP

 

What's ridiculous is that this is not a new problem. Ford's known about this since the '97 model run. Frustrates the hell out of me that their solution is to just keep repairing them IF and WHEN truck owners notice the problem.

Maybe if more and more truck owners notice the problem and take it back to the dealer, Ford will figure out it's cheaper to redesign the door instead of repairing thousands upon thousands of doors.

I hope everybody here checks their doors regularly.

I bet it wouldn't cost them more than a dollar a truck to spray some rust proofing in the bottom of each door.

 

Well put Dennis.

 

Sorry to dredge this post up but i have some questions...

Im in louisville kentucky and have a 1999 Lincoln Navigator with 60,000 miles on it.

I have the EXACT SAME RUST as you show in your pictures..exactly the same on all four doors.

I have 2 months left on my corrosion warranty and went in to have FORD look at it. They said they wont cover it because the rust isnt all the way thru the body.


What should I do?

 

My doors have this cancer as well, I am at 50000 miles now and rust is no longer covered for me unless it rusts through. I will probably fix it myself. It sucks that Ford paint quality has gotten so bad. How do the 04s look??

 

Got 25,000 on my 2002 Ford. I check it just about eveytime I was the truck, and wipe it down and still no signs of rust (knocking on wood). we don't get any snow down here so that means no saliting the roads, which probably has something to do with that.

I've heard of people wiping some sort of grease down in the cracks to keep it from rusting. Anyone else heard of this?