I just bought my wife a new explorer from this same dealer in September so hopefully they will try the best they can to resolve this for me.

 

I didn't know ford had a corrosion warranty?

 

You should be under warranty.. Your dealer should be able to make the call if it's warranty or not. Sometimes they just want to be sure and ask the Rep. Poke around with a small punch on a rusty spot and see if you go thru, I suspect you will. Look up under your truck along the rocker panels. You will see a bunch of holes taped up with black tape. If the tape has fallen off, re tape up the holes. Dirt and water can get in there and hold moisture.

 

That cab corner rust is about as common a phenomenon as my wife's nagging. That said, in my 2004 after fixing with body filler (because it got really bad) I drilled a hole underneath to allow moisture to escape and sprayed the bejesus out of the inside of hole with Krown rustproofing. It worked thus far for for 2 years.

 

For you guys with rust, are the butyl patches still in tact on your inner rockers? Also on my 11 super crew the area right under the bottom part of the rear door corner was getting sandblasted from road debris right on the under leading edge side of the cab corner. I had the area under there bedlinered.

 

I don't think the patches under there matter as much as some may think. To be fair, water, salt and debris all drain down both edges near the windshield, down the inner fender and into the rockers. You'd also be surprised how much stuff you'll find behind the front lower inner fender if you remove part of the wheel well splash guard.

Bedlining the outside cab corner probably wouldn't do much as it rusts from the inside out.

 

My inner rockers and cab corners are sprayed with fluid film twice a year along with the whole inner cab area as well. Those butyl patches play more of a role in keeping crap out your rockers than you think. Mine look like brand new inside and my truck is a 2011and I live in PA.

 

dealer wouldn't warranty mine. It was an Arizona truck it's whole life.

 

Warranty starts on the in service date not the build date. You may still have some time!

 

I sprayed a half gallon of fluid film in every crevice I could find in my truck this fall, I hope that helps.