With all the posts lately about the rust appearing on Expedition & F-150 doors I decided to call the local Ford dealer body shop. It was interesting that the body shop manager took over 5 minutes to tell me about the same door rust she had with her '97 Expedition and how she made the dealer fix it twice (this was before she worked for Ford). Since my truck is just over 5 years old, the manager told me to call the 1-800 number and see if they would do anything for me. She told me to do this because as she said "you'll find this problem with almost all Expedition & F-150's from 1997 on." I called and long story short... "suprisingly", they can't do anything for me at this time and are unaware of the problem with these trucks. According to Tina at Ford, their policy is to forward problems like that to their engineers. I really hope the engineers get this complaint, although I suspect they're actually already aware of it.

I encourage other owners with this problem to call them at 1-800-392-FORD (3673) and tell them of your rust problems. Also, have other owners with these problems do the same. I insist these vehicles are WAY TOO EXPENSIVE to be rusting like this after only a few years of age. Quality like that is unacceptable, particularly at in a $40,000 - $50,000 vehicle.

If anyone knows any other ways to make Ford aware of this through specific E-mail addresses or other ways to contact them. Please post them here.

 

You must be on the east side, cuz my wifes exped is a 97' and there aint no rust at all. But when i wash it i also take a brush to
the inside of the wheel wells and in places that deposites might
accumalate. Hum.

 

Yea, ever since I heard of this problem, I have been watching my doors closely, waxing them around the seems and keeping any crud from building up... My truck is only 3 years old, so i hope this is not an issue in the future, I will be pissed....

 

Just checking if we are talking about the same problem. If you are talking about rust on the bottom edge (seam) on the inside of the dorrs, then, yes I have it too. I will be calling as well. I have a 1999 XLT, FYI. For the rest of you guys stating no rust,,,,,are you checking the inside bottom lip???


BigMan

 

The doors are fine I mean i wipe EVERYTHING down but up here in
washington rain is a good cleanser no salt.

 

Yes, the bottom inside lip is the one I'm referring to. I have it on all four of my Expedition doors.

 

Yes this is the problem I posted on a few days ago. I also found the same pattern of corrosion on the tailgate. Mine is a Navigator 2003 less than 3 years old with 45,000 miles. It is in the dealership right now and I am waiting for their response to this unacceptable problem. One thing I noticed is that there is no seam sealer on this vehicle. Can others check whether this is the same on theirs as I would like to know if this is normal practice for Ford

 

My 2000 EXPY has the same problem and when I looked on the web, I came across something that is similar to a TSB. I could not find it under TSB's on this site, but the number was 01-9-8a with a publication date of May 7, 2001. This document looks like a TSB and give s exact details to the dealer on how to fix the problem on the doors and tailgate. Apparently they used inferior seam sealer during manufacture. It also states that it is covered under the rust warranty.

When I called my dealer, he indicated that he knew about the problem and the fix, but that it was not covered under warranty because it is not "perforation". When I called Ford Canada, I was given the same line. Perhaps it is different in the States. I fixed mine myself and have not had problems after two years.

Hope this helps.

 

How did you fix it?

 

UltimateNavi- you're what got me fired up to call Ford again. PLEASE let us know what they say on yours! Which seam are you referring too? I looked at my DS door again and the rust is worse than I remembered. I don't remember seeing seeing seam sealer coming out. I'm hoping to upgrade to a newer Navigator in a couple years, but may not if the rust issues are there too.

EagleDakota- I got the same thing too, The lady @ Ford's 1-800 # told me there is a rust warranty for 3 years, 36K miles and then the "corrosion" warranty goes for 5 years or 100K miles. The corrosion warranty does have to have "perforation" rust, which means through the body panel. If you find a good article on fixing the rust maybe we can post it in the technichal area so others can perform the same on the truck, cause as Ford told me, I'm on my own

 

Still waiting to get it back, it was also at the dealers for the following other problems:

1. Rear axle whine
2. Rattling doors / body over rough roads
3. Exhaust system muffler baffle broken and banging
4. Slight engine shake at idle
5. Center plastic caps on alloy (non chromed wheels) badly deteriorated
6. 45,000 mile scheduled service

I called at 5.00 pm and they claimed to be still working on it and estimated it would be ready tomorrow. I asked about the rust on the doors and the service writer said that the service manager is in contact with Ford on this one and will know more next week.

What I meant by the seam sealer is that on many vehicles there is a material almost like a calk applied over the folded seam around the inner edge of the door. I assume this is to protect the edge from getting water and or salt to penetrate. I noticed the Navigator doesn't have this which makes it more vulnerable to corrosion IMHO.

I am expecting to get the brush off from the Stealership (Lincoln / Ford) but I am prepared to really push on this one. I may be wrong, but I can't imagine that this is normal wear and tear after just less than 3 years.

 

Yeah definitely push it, especially on a Gator, those things sticker at like $60K and if they even say that's normal wear and tear I'd be really......Upset to say the least!

 

Got the Navi back at 12.30 today

1.45,000 mile service $176
2. Dealership couldn't hear the axle whine!!!!
3. Dealership stated the rattling over rough roads was normal for a large truck and was due to chassis flex. I pointed out that the Aviator the dealership shuttled me home in was quiet on the same route. Service advisor stated that this is because it is a smaller vehicle and doesn't flex as much!!
4. Center plastic caps on back order (apparently everyone wants them)
5. Center muffler on order expected on Thursday
6. Corrosion of 4 doors and tail gate - Service Manager has to contact Ford for evaluation. Should know some thing by I take it back next week for the muffler to be replaced.
7. Rough idle - apparently reprogramed some software but it doesn't seem any better.

 

Good thing I bough extended warranty on my '05 F-150. I almost bought 2000 Navigator, now I'm glad I didn't.

 

I think everybody is missing the problem. The rust is not originating from the outside. Any water that leaks into the door cavity from the outside will wind up at the bottom resting on that seam so the seam stays soaked for some time, rust...

I would hate to think that the window seals, door seals are bad enough to leak that much rain water. I think the high pressure car wash wand is more the problem when we start spraying in a level line at the truck hitting seams and cracks not designed for that kind of pressure.

I know that if you open any door you will find seep holes for this water to drain BUT what angle do you leave your truck parked at? Is gravity pulling your water towards the seep hole? I know that my drive way is at a pretty good angle with street level being lower.

Geo!