Hello all. I have been a happy owner of my 2009 F150 FX4 Crew over the last three years. I bought this truck used out of Michigan. I'll stay away from Michigan trucks after this, lol. I noticed bubbling over the last six months on both cab corners. I was prodding the drivers side last night and poked a nice large hole through. The passenger side seems more solid but probably not for long. I have researched the why and the flaws of drain tubes exiting back there. I spoke with about three body shops today and this is what they said.

Carstar place will send me and estimate at the end of the week. I expect about $2000 for cab corner replacement. I think $2500 would be my cut off to keep and fix this

Local body shop #2 told me it would be close to $4000 and they were honest about it and said just sell the truck instead of sinking money into it that I will never get back.

Ford Collision center basically said they wouldn't warranty it and the would have to replace the panel half way up the body.

It's seems that it is going to be cost prohibitive to fix this. I was only planning on keeping it about 2-3 years before going to a 2015 FX4. I owe about $11,000 on it and probably will sell it this fall. It might just be destined to be a work truck of fixer for someone who is good with body work. Hopefully, I can stay with the newer F150. It has been a good truck for me.

Thanks for listening to all this

 

Seems on the high side for this type of repair. I'm pretty sure they sell the cab corners now as body shop replacements. If nothing else, get some diamond plate corners made like you see on jeeps and epoxy it on, better than driving around with the holes and cheaper than 2k.

 

I have the same issues on my 2011 FX4 I just got all the rust out on one side, put some rust inhibitor inside the hole, filled the hole with sealant foam, then I used bondo bodyfiller to patch up the hole. the other side isn't as bad but in a couple of months I will be in the same boat. I still have not painted it yet but when the weather is warm and I can find the correct piano black for my truck I will sand it down and paint it. NOT the perfect fix but my truck is a work truck so sinking 2-3k into it for rust isn't worth it to me. if you look up rust fix on youtube you will see all kinds of videos. they also make the plate corners as was forementioned after I do the paint and repair, I will most likely try to find some black matte side panels to cover it permanently and prevent more rust.

 

My 2013 is rust free and flawless EXCEPT for the cab corners, specifically the passenger side rear corner. There is bubbling and rust stains showing through on the exterior. Ford denied warranty coverage even though I was within time limit because it wasn't a "total perforation" that you could stick a finger through. If I had known that was their stupid rule, I would have taken the truck into the dealership with a nice gaping hole there. Oh well.. will buy something different next time around.

 

For the record.. does anybody know HOW the water gets in there? I don't have a sunroof. My 3rd brake light is sealed off well. I have fresh tape over all my inner rocker factory holes. Yet, my rust continues to get worse. Where is the water coming from?

 

 

I removed all the factory tape from the bottom and damn near filled my rockers with fluid film. So far no rust yet, but as soon as I see a bubble I'm selling the truck. I hate rust that much.

 

Yeah mine is growing at an alarming rate. 4 months ago I had a small bubble that barely left a rust stain. I taped all the holes, sprayed rust preventative inside, sealed the seams on my roof, sealed my 3rd brake light, etc. Yesterday I noticed that the spot is twice as bad and there is now a new bubble forming above it. Apparently that cab corner has cancer really bad.

I'm like you...the thought of spending thousands to repair rocker panel damage in a year or two makes me sick. I actually tried to trade my truck in this morning on a new one. Waiting to hear back from the dealer.

If it doesn't work out I guess my next step is to seal off the entire edge of the rear glass. I don't know where else the water could be coming from.

 

What I don't understand about your truck is the lack of road salt in Kentucky. Here in Michigan there's more salt than snow half the time. I flushed my rockers and oiled the hell out of them as a preventative measure before I ever saw any rust, and will continue to do so yearly as long as I need to. It's a steel body and I live in Michigan so I know I'm fighting a losing battle, but I'll give it everything I can. I love my truck, and it's paid for so it has that going for it. Not too keen on dropping $60K on a new one. I don't want another steel one, and I liked the 15-17's until I saw how much better the 2018's look. Who knows, maybe I can fight the rust until I can get a good deal on a low mileage gently used one. I'm going to have my front end resprayed this year because I hate rock chips. I even went so far as to purchase another bumper that I'm going to have painted at the same time, and then let it sit and cure for a few months. Once the paint is fully cured I will put a clear bra on it, and then swap bumpers. This way I don't run the risk of chipping the fresh paint. Yes, I am that OCD.