Ford F150 Rusted Rocker Panels - It's Preventable And This Is How

The rust hole that appeared in my 2010 was a result in my opinion of the fiber patches either not applied correctly or not applied at all. I do like the design Ford had made to allow easy access for the phosphate and elpo dip to flow easily through the rocker panel. On my truck many of the patches were missing or fell off and where the rust hole was the patches were absent. I must say the truck otherwize has been a terrific truck and would buy another one . Hey stuff happens so just check yours and take the opportunity to apply rust preventive before you reseal the holes if you like. Cheers


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[firemedic]

My 2010 F-150 has been garage kept and washed regularly especially in the winter to keep salt off of it. My rockers are rusting out significantly on BOTH sides with large holes appearing on the crew cab where it meets the bed. The weather stripping is losing metal to adhere to. I’m the owner of this truck. 170k miles. I’ve maintained it very well and it runs great. I think it’s absolutely RIDICULOUS that the engine will last longer than the body will!!! Thank you for this informative video. Shame on Ford for screwing us like this!

[kevinroback]

Just had my 2013 fail it’s safety due to rusty holes in the rockers. Then I went underneath to check and saw the taped up holes and thought it was the undercoating company who did something stupid like this. But you just proved it was Fords best engineers who thought of this design! Wow!!
Thanks for the vid. Thumbs up

[jim]

Nice Video. I am dealing with rocker rust now. I cleaned them up with a wire brush. I bought a gallon of Total Boat rust converter($29) to spray on and inside the rockers. Did two coats. Then painted with metal primer and top coat. Lastly will dump in some used gear oil from my outboard lower unit. I will also do the same thing to the doors. The window seal fails and you get water in the bottom of the door. Remove the rubber grommet at the bottom of the door for access.

[jeffntexas]

Maybe you already covered this in another video, but another potential area of rust is the bottom of the doors. Debris falls down through the window opening and plugs the drain holes along the bottom of the door. I discovered this when I heard water sloshing around in one of my doors and found dirt plugging the drain holes. I check them regularly now to make sure the holes are clear to drain.

[bryanteuler]

Majority comes from the third brake light leaking and allowing water in and they rot from the inside out. There was a tsb put out at one point for it.

[stanleykania]

Designed and built for Wall Street.. Mine is a 2012 and bought new.. the first thing I did was Rustuleum paint undercarriage and I put silver duck tape over all those holes and painted over them.. Today I was under it and cleaning winter salt out with air hose and painting and that tape is still good !!

[GrantHubbard]

My GMC came out of Canada about 3 years ago...now the rust is really starting to show :( cheers brother

[elkameno]

Just to add my rotted rockers and cab corners to the group, 2010 98K miles . Rockers have been gone since '18. Of course weekly washes at the carwash (yes paid for the extra wash for the frame and wheels) . $2, 000 + for replacement. Truck owes me nothing but I'm waiting for it to fold in half when I hit a bump.

[gene]

Had to share this with my OSHA Ironworker instructor today, he just got a 13 and if nobody tells you about it you'll have a nice rusty truck!!! The last rear rocker hole has an access hole to the outer side of the cab corners that must also be waxed or...I used 3M cavity wax with the 360° spray wands, pricey but worth it then used rubber gorilla tape. And the doors have access holes with grommets just for this, go figure and don't forget your brake light gasket, they leak to, Amazon has good ones. As for the foam in the wheel wells that's getting tore out to I decided, then coated again, holds enough moisture to cause rust, tore some out and tested it in glass of water. Fabbed and welded up one corner and a small spot over the wheel so I should be good till one of us wears out completely 🤔, it's a 14 btw.

[michaelkennedy]

That could be part of your problem, but if you have a sunroof Ford ran a drain hose down the inside corner of your cab. Allowing the cab corners and rockers rotting out.the drain hose did not exit the truck; they are about 10” short allowing the cab corners and rockers filing up with water.

[russriley]

i have seen examples of body parts that trap water and dirt inside them for years.the common problem is there is no drainage at the lowest point of these parts. i remember cutting into a camero quarterpanel that actually leaked water as i did so

[GrampiesWorkshop]

Well there ya go ... just when you thought rust issues were no longer and issue. Thanks heavens for Ford, trying to keep the body shops in business!!! Have a good week buddy!!!

[wyattoneable]

Working under the truck is nasty stuff but it sure makes you feel better knowing you extended the life of that dude.

[jamieemes]

I'd use peel and seal for roof repairs. It sticks like crazy(kind of rubbery/tar like and can get with aluminum foil type coating on outside.

[curtiscastle]

great video Steve, wait to call a spade a spade. You know another funny thing is they also have a drain tube running out into the cab corner that (I guess) is a drain for the third tail light or rear window, but the thing just drains down into the cab corner with no way for the water to get right out. Would have laughed my ass off except that I discovered it only after having to fix the rust.

[jpowell]

Nice find.
There is also a fold in the rear rocker to cab corner you can stick your baby finger in there.. mine is a 13 and spray it with oil every fall. Looks OK so far.
I shoot oil in those holes where I can and most places drill hole and plug them when undercoating.
If you don't spray them also up inside the box panel the top rusts above well and up where plastic box cap meets paint.

[AndreasvonT]

I found tape like that on my 2005 dodge Ram a few years ago so I pulled it all off and blew a bunch of ATF oil inside the rockers and replaced the tape with gurilla tape. That stuff sticks like crazy. Luckily my rockers are doing great. I also drilled some big holes from the inside of the truck box so I can wash out the inside of my wheel wells. I blow ATF oil in there too a couple times a year. So far i have been able to prevent rust showing on the outside of the vehicle. There is some surface rust underneath but I soak it with oil every year.... Seems to be working.. fingers crossed! Lots of salt on the roads here for about 7 months of the year

[guffylips]

Yes, my 2010 F-150 rocker panels are shot. The paint started to peel at 55000 km, on bottom of doors and rockers. The dealer told me it was because of sand and gravel, I told them at that time it was mostly highway miles. Story short i got a rusty old truck now and it 's my last ford.

[michaelmurray]

I have a 2009 F150 with only 72, 000 miles and both my driver side and passenger side rocker panel is rotted out and need to repair soon.Thanks for sharing ur video it’s a bad design of rocker panels with such huge holes..

[lynnmoore]

Doesn't surprise me at all ! I seen a lot of crazy things on the line at Chrysler back in the day! Nice video Steve !