I'm seeking feedback on how many other Super Duty owners are experiencing complete outer body rust through at the rear wheel opening. I've got a 2006 with 105k and absolutely beautiful body... except at the rear wheel openings.
I'm amazed that a vehicle this clean can rust through in 5 years and not be covered by a corrosion warranty (expired in March..... rust discovered in June!).
Looks like it is rusting from the inner fender/wheel well seam and up the inside of the body... wheel lips appear as if fresh from the factory.
Anyone experiencing this level of rust? Ford says.. too bad.. warranty already expired... but what sort of company builds a truck that rusts through in 5 years???? I've been a loyal Ford and SD buyer for years too... maybe no longer.

And.... I keep the vehicle in top mechanical and appearance conditions. It's not a beater at all...... feedback anyone?

 

Many of us have or have had the same problem. Especially if you live in the rust belt somewhere. My truck still looked brand new execpt for the bubbles starting in the wheel wells. It's caused by a foam that is in between the wheel pan and the inner side of the quarter. I spent $3k last year with a longer term solution. Call it what you want either fix it or patch it and move on.

 

my 99 just started poppin last year! buddy has an 06 an his started before mine! very common on these trucks! it sucks but thats why as soon as you see it, get workin on it!

 

my 2003 has ZERO rust in that area..

so you cant say its a FORD design problem..

its the area you live in..some areas simply require more work to keep rust at bay then others.

 

My 02 looks like the outsides of the box is going to rip off in a stiff breeze, just check my garage pic. My 'other pickup', from another company, was over ten years old when it started to pop through. Just differences in construction by the looks. That foam stuff seems to hold moisture or some thing

 

Could some of you guys add pictures?

 

From FBH's garage:

 

If I was designing a truck to rust out around the wheel arches I would probably put foam inside the wheel well.

 

I guess I got lucky and caught it just before warranty expiration on my 06 and thanks to Ford it got 2 new bedsides! But as of a few weeks ago I no longer own that truck. It's a combination of that foam plus rough winters (salt use) here. That water/salt combo leaks down between the seams and just starts eating away. If you want the trucks to stay relatively rust free you have to garage them from November until May so they don't get blasted by salt. It's rediculous knowing you are dropping some serious money on these trucks only to let them rust away in these rust belt areas. My garage isn't tall enough to fit my truck but it sits in the driveway for most of the winter, unless I can't resist playing in the deep snow! The next house will have a garage tall enough, or I'll make it tall enough. But in the next few weeks I'm going to start preping for the winter by fixing any surface rust underneath and where to pieces of sheet metal meet. Then grease all the problem areas before the snow flies. I think the foam thing was goofy but Ford doesnt choose where you live. Vehicles in the southwest seem to do very well. They could probably make rust resistant cars but I can't even imagine what that would cost. Get the grease out and make those trouble areas resistant to water.

Think about the people with great looking older muscle cars. They always have shiny paint and look great. Why..... those vehicles have never seen salty roads or bad weather for that matter. If you need the truck for business purposes, especially plowing, and use it everyday then you should have replacement built in to your business plan, or buy cheap trucks so you don't care what happens, or lastly live where salty roads just don't happen.

 

https://www.ford-trucks.com/forums/9...ml#post9132066

 

No salt used here. That means no surface rust, let alone bubbles or rust through....

 

Man that must be nice.

 

I have flares, I'd hate too see what it looks like under them. My tailgate pinch seam is what is rusting on my truck.

 

I've found tricks to help keep this down.... After the winter I get a gallon of ospho rust inhibitor and spray on the back of the quarter panels of my box, inside of doors and the front fenders. I do it either or not I see rust or no rust. My truck is a 99 and it looks like it just come off the show room floor and that's with me plowing with the truck also. I think a jug of ospho costs $40, to me that's a hell of a lot cheaper than body work or a new box.... Oh and spray on bed liner of the ospho. Who cares what it looks like no one will ever see it

 

I just traded a 2000 F250 in on my new truck that had no external rust and it was almost 12 years old. There was rust under the truck but nothing rotting off. Did have to replace the cover on the rear end last summer......