Expy Door Rust
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New User
Joined: Aug 2003
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Expy Door Rust
Anyone have problem with rust at the interior bottom of the doors? Two of my four doors have surface rust. The rust is not due to lack of maintanance, I wash regularly and always wipe/dry the door jambs and doors. Perhaps there is a recall or record of this happening? Thanks!
Logistics Pro
Joined: Oct 2000
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From: All over Texas
Expy Door Rust
This has been a huge problems with some early Expys and newer generation F150's. Some have even found cracks on the front doors. Check with Ford for recalls/assistance. Don't these things have very long-term corrosion warranties?
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Joined: Sep 2002
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Expy Door Rust
Welcome to the Ford Expedition Door Rust Club.
My 1999, driven in the rust belt, is developing this, particularly on the driver's door. I wash my truck at least weekly, and the rest of the vehicle is spotless. My theory is that the running boards allow just enough salty water/slush flung off the front tires to creep in along the bottom edge of the door, but prevent the water from automatic car washes from properly flushing this area out.
The cure is obviou$, unfortunately. Take care of it early, before the rust creeps around the bottom of the door and spoils the exterior paint.
My 1999, driven in the rust belt, is developing this, particularly on the driver's door. I wash my truck at least weekly, and the rest of the vehicle is spotless. My theory is that the running boards allow just enough salty water/slush flung off the front tires to creep in along the bottom edge of the door, but prevent the water from automatic car washes from properly flushing this area out.
The cure is obviou$, unfortunately. Take care of it early, before the rust creeps around the bottom of the door and spoils the exterior paint.
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Joined: Jul 2003
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Expy Door Rust
My '98 Expy was developing rust at the bottoms of the doors where the lip is wrapped around underneath and sealed. I had my truck at the dealer for service a few months ago and while it was there the body shop manager took it upon himself to inspect the doors. He told me that no rust preventative was applied in these seams at the factory, allowing water from the window seals to rust the doors from the inside. Ford has actually developed a tool to split the seams open so that they can be rustproofed and resealed. This is about a $ 1,000.00 repair for all four doors and the liftgate that was done on my truck for free because it was still within the 5-year rust warranty. This isn't a recall, so take it to your dealer and have the body shop check it out. They'll probably be very happy to make the repairs and charge the cost back to Ford. If you wait too long, the rust will start coming through the outside of the door skin and you will have a very ugly problem to deal with.
Junior User
Joined: Jul 2003
Posts: 72
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From: Florida
Expy Door Rust
Yep, same problem here. My 2000 5.4 EB has rust at the bottom door crimp on both passenger side doors. I am going to attempt treat it myself soon. I don't know if it has spread through to the outside surface yet because there is a piece of plastic molding covering that part of the door. Thank goodness for that piece. Even if I can't stop the rust from spreading, it will probably never be noticed from the outside.
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Joined: Sep 2003
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I have the same rust problem on all 4 doors of my 2000 expy. I went to the local dealer and he tried to get Ford to own up and cover the cost of fixing the problem. However, Ford said no way, claiming that because there were no rust perforations, they would not pay - even though "in theory" the Ford warranty for rust is supposed to be 5 years.
At least the local dealer feels my pain and is going to cut me a deal on doing the repair. Gotta love manufacturers who stand behind their product.
At least the local dealer feels my pain and is going to cut me a deal on doing the repair. Gotta love manufacturers who stand behind their product.
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
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From: Blue Hill Township
I don't have that problem. I live in MN, and they are really heavy on the salt. I think that it is because I had the truck undercoated with rust proffing at Zebart, and they did the door bottoms as well. Every year, they will check it, and repair any underbody rust at their cost. and touch it up.
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
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From: Blue Hill Township
I have 47xxx miles on the truck. I have been very happy with Zebart. I had the stuff put on when I first bought the truck new, and I would do it again in a heartbeat. The only thing is that it will smell for a week after they coat the entire underside. After that, on the touch ups, it doenst smell for more than a few hours. Well worth the money in my opinion.
Senior User
Joined: Sep 2003
Posts: 186
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From: Detroit
Thanks, I've been looking for a solution.
Anyone heard of a product called Rust Check? It's a clearer and thinner than Zebart. They claim it stays liquid and therefore gets into the smaller areas better.
Anyone heard of a product called Rust Check? It's a clearer and thinner than Zebart. They claim it stays liquid and therefore gets into the smaller areas better.
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