Just recently gave my truck a good thorough cleaning as we had a warm spell last week and noticed rust on the bottom of each door. The rust is at the point where the outer door skin is folded around to the inside of thedoor frame near the weep holes. I can see some orange surface rust as well as some bubbling of the paint.
This is nothing new to me as My 1997 Merc Mountaineer had the same problem. The dealer scuffed it up and spray painted it a couple of times and after many arguments and conflicts and returns of rust they finally took the door skins off and low and behold the was an infestation of rust all along the bottom of the door frame. They supposedly cleaned it down to bare metal, treated it, painted it and welded new door skins back on all four doors and replaced the tailgate. Thats when I promptly traded it in for a new Super Crew.
The saga continues on the 20th when I bring this one to the dealer. I tried a different Ford model last time, maybe I have to get a Chevy or Dodge
To all: Check the bottom of your doors.......good luck

the rust is hard to see but, in the center of the photo is the bubbling and along the seam is the rust

 

I was afraid this was still a problem. That's why I made it a point to have my '01 rustproofed and undercoated. I've also read that another rust spot area to watch for is the bottom of the tail gate.

I also wipe off that area every time I wash my truck. I also wax it a couple of times a year.

 

this suks. has anyone tried those electronic rustproofers? i would like to prevent this before it starts. here in NY we get tons of salt on the roads this time of year.

 

Thanks for the heads up, I will be checking my SCREW out tonight and will be sure to keep that area dry.

 

I think Ford tried to get sneaky on us. My 97 suffered from the same problem - rust all along the bottom of the door. My '01 Crew has a plastic "guard" over the portion that was rusting so it isn't easy to see the rust. I am going to lift mine tonight to look for that pesky rust!

Thanks for the heads-up!

 

it reallymakes me wonder where ford is gettin their sheetmetal. if you askme these shouldnt rust in any way shape or form for at least 5 years. unless there was a scratch. they have had this same problem since 97 and these "ENGINEERS" cant figure out how to fix this? hard to believe.

 

You can say that again. My 2000 SCAB started showing it in the tailgate and driver door at 15k! I'm hoping I can delay it further on my 2001 SCREW......

 

i was wondering how you made out at the dealer gettin this fixed. i checked mine i have a couple of spots ready to pop out. is your truck still under warranty?

 

All 4 of my door bottoms are rusting. Creeping from the seam bubbling the paint. Had it repaired under warrantee, poor job, failing now 60 days later. Ford says "we paid once" dealer says nothing can be done " its a ford problem", bla bla! I cannot allow the door skins to be replaced, that will lead to more dissapointment. So I repaired it myself (hope to gain on it) Should be covered, but I cant stand the runarround, etc. Maybe another brand of truck is the next fix for me..........

 

It's a shame to have to say this, but you really need to get the doors rust proofed. Otherwise a few squirts with Corrosion Block or Corrosion-X would go a long way to preventing AND stopping rust in the bottom of the doors.

 

It's a problem on my 2001 with 30K.... used a little rustoleum on the bottom but I am afraid it is from the inside. Can't imagine the dealer actually fixing this without it looking worse.....

 

I'm dropping mine off Monday at the body shop. The owner of the shop said they are just going to sandblast the area clean, paint it and then apply some rust inhibitor.

I don't know....My last vehicle had the doors ripped apart and the rust was inside.

 

The problem is that the rustproofing that ford does at the factory is some type of parifin wax which does not pennetrate threw the folded metal seam at the door bottom. The door is crimped together prior to priming, so the metal inside the fold is not protected, so it rusts. There is not enough paint applied ( in fact on mine some areas on the door inside you can see primer threw the paint) to seal the seam. Without any seam sealer applied moisture can form and/or pennitrate the seam causing the rust which is creeping up under the paint above the seam. Anyway I have rustproofed the inner door with a restoration product calles NORUST which will pennetrate , however, fords wax has sealed the door bottom and will not allow pennetration from the inside??? What I did is clean it well, applied Sikkens CR etching primer, 3M 8300 seam sealer, and Urethane paint. Now this winter will be the test, has to last longer than the 60 days fix I got from the dealers shop. This concept is to seal the rust from the inside and outside, no oxygen, no moisture, should = stop further rust. It wont change whats there, however I dont want the doors messed up having the skins replaced so this seems like its worth a try. I have a lincoln and a mustang without problems and both have the seams sealed with seam sealer prior to being painted......... good luck!

 

S66,
Thanks for the info. This winter will be my test as well. I may have to try it myself with your method if the body shop doesn't do the trick

 

I have passed the dealer repair time of 60 days without a sign of failure. Will see in the spring how the repair winters threw in the salt belt....