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I am sick that my 2008 F250 with 107K miles is exhibiting signs of rust this spring.. While filling up the tank saw a bit of a bubble on the left side top of the wheel well. Another one on the passenger side. I've had the truck since new and have tried to keep it as clean as I can being that it is a daily driver in the rust belt. Certainly thought that I'd get more than 6 years before the rot showed up. Don't remember my 1999 F350 exhibiting that, but it was a dually and had the fiberglass fenders that might have hidden it.
Took it to the local body shop and he told me to get used to it, just a matter of time around here. He said he could work on it, but it would never be fixed, rust would eventually return. He suggested sand blasting myself, repairing as I could, oiling the inside behind the tail lights and bolting on some Bushwacker flares.
Anyone else finding this issue? Having driven Ford trucks all my 40 years of driving I'm going to be looking at Dodges next time I buy.
the dodge will make it 2 years before it rusts...LOL
A guy at work has an 08 Dodge and you can stick you fingers through the holes perfect truck other than the rust over the wheels as Wells. My 04 is just starting to rust and I am looking at fender flares as well.
That's frustrating for sure, but unfortunately not a new problem. I'd recommend making sure whichever brand you jump to is immune to these issues before spending your hard earned money.
Unfortunately its a design issue and it will take a good amount of body work to eliminate it. Ford used an expansion foam to seal up the gaps why, I have no clue. Over time the foam becomes a sponge that holds salt and water.
The only way to fix it is have a body shop cut out the fender wells and remove the foam. It will not stop the rust but It will slow it down some.
You can try to undercoat it with Fluid Film and slow the rust down. Sadly its a product of salt use. Its not just Ford that has wheel well rust issues.
My Aunt has a 12 GMC 2500 HD and there is already a good sized bubble on the bed well, We have a guy at work with an 09 3500 Dodge and there are massive holes in the fenders as well.
My 08 that is plowed with and almost never washed is perfect. No signs of rust at all. I can't think of anyone I know with a 08+ that has issues yet. Sorry you do but like your body guy said, it's only a matter of time
If it was me I'd cut out the affected area(go past to be sure you get it all)weld on some patch panels, paint them, soak the foam with fluid film and then buy some fender flares.
Or you could spend the extra money and replace the entire bedsides and rust proof them right off the bat.
Don't buy a Dodge, they rust just as fast or faster than Fords.
My 08 that is plowed with and almost never washed is perfect. No signs of rust at all. I can't think of anyone I know with a 08+ that has issues yet. Sorry you do but like your body guy said, it's only a matter of time
My dad has a 94 f150 with 90k original miles, never driven in snow, etc, and both fender wells are rusting through. My 92 bronco has been driven off road, snow, salt, etc and gone months without being washed and the fender wells are perfect. Same for the 97 f250 hd I sold last year. Driven in all conditions, never washed, and no rust at all. My sd has never been off road or in the snow and the bed supports are already rusting.
That being said. Is it possible the soaps are reacting negatively with the salt speeding up corrosion or is the sponge actually scratching the paint, pushing the salt in the microscopic holes being made?
I use this stuff about once a year on my entire undersides as well as every body panel hole I can stick a spray nozel into. I dilute with 20% water to help it flow thru a pump up bottle better.
this stuff will freeze rust and provide a protective coating.
I would'nt even waist my time with patch panels. I would replace the whole bed side and call it a day. Look at your box supports as those go bad too.If they are going bad then it's not worth fixing as you can find another box for the same price as it would cost to rebuild it, thats if you do it yourself. I feel for ya!!!
Your wheel well rust is a function of road salt and humidity. Once fixed, you need to drown the underside of the truck yearly in ATF or gear oil, and soak all rust-prone areas. The bed supports may be mostly gone, too, so check those now and buy a pump-squirter oil can, fill it with oil, and start hosing it down. I hope you have a dirt driveway ;-)
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. While filling up the tank saw a bit of a bubble on the left side top of the wheel well. Another one on the passenger side. I've had the truck since new and have tried to keep it as clean as I can being that it is a daily driver in the rust belt. Certainly thought that I'd get more than 6 years before the rot showed up. Don't remember my 1999 F350 exhibiting that, but it was a dually and had the fiberglass fenders that might have hidden it. 
