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1999-2007 General Questions General questions related to 1999-2007 Super Duty trucks. If it doesn't fit the other categories, post it here. Gas engine discussion that pertains to all models is allowed. Specific gas engine questions should use the Gas Engines forum.

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Old 08-31-2008, 07:51 PM   #1 (permalink)
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Rust problems anyone?

Have a 2002 and already have about 5 bubbles coming up on the rear passenger side wheelwell. Just wondering if anybody else were having the same problems on a truck that's just 6 years old?
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Old 08-31-2008, 09:41 PM   #2 (permalink)
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I have the same problem on my 01', only I have it on both sides on the rear fenders
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Old 09-01-2008, 11:57 AM   #3 (permalink)
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Wow. Anyway to really stop it where it is and possibly fix it?
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Old 09-01-2008, 01:43 PM   #4 (permalink)
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The problem is they use a foam type sealer/adhesive on the inside of the quarter panels.The foam retains moisture and causes the panel to rust from the inside out.The right way to fix it is to cut the bad metal out an d put in a patch.We've done a couple at my work.The trucks have a 5yr warranty for body rust.
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Old 09-01-2008, 11:08 PM   #5 (permalink)
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Man didn't miss it by much then. Just sucks that have to have this headache now!
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Old 09-02-2008, 05:39 AM   #6 (permalink)
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Originally Posted by my03psd View Post
The problem is they use a foam type sealer/adhesive on the inside of the quarter panels.The foam retains moisture and causes the panel to rust from the inside out.The right way to fix it is to cut the bad metal out an d put in a patch.We've done a couple at my work.The trucks have a 5yr warranty for body rust.
Yep,

I had the left wheel well done @ the body shop. The foam isn't needed @ all, it collects rust and causes headaches. Mines all repaired, I will keep it clean and dry of road salt and sand.

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Old 09-02-2008, 04:33 PM   #7 (permalink)
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My '99 has a lot of undercab rust beginning, bottoms of floorpans and along rockers; when the bed bites it and burns through it will get the poorboy fix, a flatbed for real work and it will become THE farm truck.
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Old 10-04-2008, 08:44 PM   #8 (permalink)
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I have the same problem, on my 2002, both wheel wells. I got an estimate from the dealer and they quoted $1773.36 to fix it, they say to cut the rusted spots out and replace with new metal and paint. They also take the bed off to do the repair. What do you guys think of that price?
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Old 10-07-2008, 05:53 AM   #9 (permalink)
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Big bailey,

Price seems about right for the work. I paid $1064 to have the bed removed, old rusted bed crossmembers replaced and left rear wheel well cut out and replaced.

The body shop took about 3 weeks to do the work.

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Old 10-07-2008, 07:37 PM   #10 (permalink)
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The price doesn't seem bad, but 3 weeks is way too long for that job unless it was a fiil-in.
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Old 10-07-2008, 10:36 PM   #11 (permalink)
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Only rust problems I have on mine is on top of the cab, I think I have around 3-4 blisters forming up there. Fricken sucks!
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Old 10-07-2008, 10:46 PM   #12 (permalink)
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I am going to visit a local body shop this week and talk to them to see what their thoughts are before I move forward. Anyone fixing the rust and covering with fender flares? Ideas?
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