I gave my truck a bath today, and was cleaning around the doors and found this, its only on the passenger side, luckly its only on this side, its not yet noticable on the opposite side. sucks to find it since my truck only has 50,000 miles on it. whats the best way to fix it, I put some rust converter on it, it seemed to stop the rusting on my old car. but it wasn't quite this involved or this big. I'm just happy I found it now and not when it made its way to the other side of the door.

Up Close

Rust2.jpg?t=1179785271

Far away
rust.jpg?t=1179785334

 

I would knock off all the loose paint with a flat blade screw driver, but carefully so the paint doesn't chip off onto the other side. Then you can put on several coats of rust converter, and then after it dries (according to the instructions), you can spray some primer over it (if required) and then spray paint over it. OR, after you get the loose paint off, you can put some por 15, or similar that is designed to stick to rust and stop it.

If you want it to look real good, after you knock the loose paint off, sand the edges so it goes smoothly from metal to paint, then continue with the rust converter and put some bondo over the rust pits (if they are big enough), then primer and paint.

 

To properly fix it, you will have to get inside the door (including opening the seam) and grind away Every Speck of rust, apply a rust inhibitor, and repaint. Judging from the condition of your door, I'd start looking for a new one.

 

yea, I think i'm just going to eventually replace it, but I need to do something that'll just keep it looking nice till I get the whole truck redone in late July early August. so i'll just check the scrap yards for a door. and have it put on then. should'nt be too hard to find a 01-07 XL door, in oxford white

 

I have the SAME EXACT PROBLEM, on the same truck and same door. Last year, I sanded the entire area and primed and repainted the inside with Duplicolor from the auto store. But per the previous post, this is only temporary because the issue is comming from inside the seam.

It appears Ford has an issue with drainage in this area. I'm just as bummed, because this type of thing is not supposed to happen with the newer paints and manufacturing processes.

 

the problem is water collects inside the door with no way out. Why not drill a hole in the bottom of the door?

 

Terry, did you ever get it fixed?

 

Stupid question, but isn't there a corrosion warranty on fords? I know for a fact my Buddy who bought a ranger brand new in 1995 got his doors fixed and ford paid for it. Of course his truck was anly about 4 years old then.

~HJ

 

wow. forgot about this thread. yes and no. I stopped the rust. and painted over it. it looks good from 5 away. but up close you can tell it was rusty at one point. as long as it doesn't show up on the other side I'm not going to worry about it. I
'll try to get some pictures up later of the repair

I will look into the corrosion warranty. but I'm guessing its only 5 years. and the truck is 6 years old. I did buy it used of a Ford Dealer (well, Volvo, but Ford owns them)

 

I have only 23,000 miles on my 04 Ranger and noticed rust on the bottom of the passenger door as well. Im pissed off! I only have 23,000 miles on the 04. Plus I wash and wax it reguarly. I noticed that there is a 5 year/unlimited miles corrosion warranty. Im interested in what my dealer will say. I wonder what if any technicalities there are regaurding the Corrosion Warranty....Maybe I'll just trade it in on a 2008 Jeep Wrangler before the rust gets to noticible....

 

you have to find a very nice dealer.. its a 5 year 60k i think warrenty and its for rust THREW like holes... some dealers are nice and do it just for surface rust but not always

 

you have ohio winters to blame.....mine is 4 yrs older than yours and has 147k miles on it and doesnt have a bit of rust anywhere. I live in georgia though....

 

Jeeeeez I'm glad they don't spread salt on my roads here in Arkansas!

I have a white passenger's side door in my garage that I desperately need to get rid of. Interested?

 

Update: I brought my 04 Ranger in to the Ford Dealer I bought it from, and they inspected my rust problem. Although the rust doesnt fall under what the terms of the corrosion warranty covers, they agreed to fix it. They said I qualify for a "Ford assistance program". The repairs will cost aprox. $1100.00, I will only be on the hook for $100.00, plus I get a courtesy car while the repairs are being done. The service writer stated that my good relationship with the dealer is the reason why they are hooking me up. Had I been a customer that had never had work done there in the past they would of basicly shown me the door....So I'm happy, and decided not to write the Ford Motor Co. off for life. Perhaps I'll trade my Ranger in one day for a F 150 when im done with her....(my rust problem is very similer to the pictures posted by gasman ealier in this thread)