To dpthomasjr, Are these clip slots on the door pillar behind the kick panels?
In other words do I need to pull the kick panels to see them?
Thanks for the help.

 

First check your build date. then if your flexible enough you might want to start with the pass side. remove the panel. but yes, the connector will be inside the pillar. this makes it hard to see but might be possible. (we use flexible scopes for stuff like this). i dont think it will be very easy for you to see though. you may be able to release the lever (dont just pull it down, there is a thumb lock to release before swinging the lever) and remove the door connector from outside and using a light see if water is in the channel below the metal clip.

Also, do you have a sunroof? there were some issues with the sunroof drain tubes coming down the pillers and the drain holes in the sheet metal being blocked.

im no warranty expert or anything just a component supplier. i recall hearing of these issues after the initial launch of the F150 and thought the info may help.

 

dpthomasjr- I checked the door piller where the connector from the door goes thru the pillar. The black rubber tube that goes from the door thru the piller looks like it has a tear in it and has water in the area of the tear. It looks like this may be it. I only checked the pass door because I at work and some idiot parked so close to the drivers door that I can't get it all the way open.

 

If water enters the grommet there is high risk that you may lose electrical funtion in that door. depending on where the water is entering and if it can travel to the connector.

 

Any suggestions on how to repair it. Oh by the way build date is 12/03

 

Unfortunately i dont, at least nothing that would be 100% watertight. you could buy a new grommet form the dealer if they sell it as a service part.

does the rubber grommet go to a black and grey plastic connector on the piller or is it all rubber between the door and piller?

 

It is all rubber between the door and pillar. I had one of my warehouse guys go and check it now that I can get the door all the way open and I guess I am back to square one. He pulled back the the grommet and it only looks like it is torn. Dry as a bone behind the grommet.
How would the sunroof drains leak if the sunroof is closed?

 

yep, they did not use the connectors i was referring to that early. so disregard the leaking through the connector clip slot theory.
good question about the sunroofs, id alwys thought the same thing. unfortunately i dont work on the sunroofs. i just heard of this same issue due to the drain lines.
i think water may still get in to there. just like the windshield leaking theory, it shouldnt leak but they can. believe it or not i had a new set of connectors sitting here to ship to you if you found it was those.
good luck!

 

Thank you very much for your input. It is driving me crazy. I bought the truck new in 04 and it just started this **** this winter.

 

Well here is an update on the leak problem. I am still open to ideas.
I removed the rubber floor mats from both sides over a week ago and no more wetness.
Is it possible that water could condense under the floor mats?
Anyone have this happen?

 

not that i know if....i should check though.