The first thing I noticed even on the new body style trucks is the same darned seam as the old body style. A friend of mine has an '04 F-150 and it is already starting to break out along the seam.
My '04 Heritage has a full length factory side step that protects the bottom of the doors and even in the winter no salt sludge gets on it. Some say the factory side steps are ugly but if they protect against the rust, I don't care what they look like...

I couldn't believe my eyes when I saw that Ford didn't seal the new body style seams any better than the old ones even after all the complains they had on it...

 

I have full length factory steps and I still have rust. It is not from salt sludge it is from water the comes down from above and sits in the seam.

 

I did my 98 front doors before i found the factory fix,used a Dremal and Rust Restore encapsulater 2 years ago and no rust.There always seems to be a chemical reaction with this stuff and the paint had a few barely visible cracks within 6 months but no rust.I also give it a finger full of wheel bearing or heavy gear grease once a year as it fills the pinch welds and stays there.
If the factory fix doesn't work i may stick to this methhood.Also thought about POR 15 and extending the rocker guard around the bottom of the door past the seam.I think Norm is on the money it's the very last thing to dry out on the truck.And it would seem as though there is no slope to it at all.

 

Great pick Norm! That's why I started this thread. I live in Michigan and my 03 does not have any rust in the seams yet but I know it will happen if I don't give it some kind of treatment. Has anyone just sealed these seams with body caulk?

 

You can and I believe that is what is in the Ford TSB. Unfortunately you have to open them up and clean out the rust first. I am just going to coat mine with a rust reformer like POR15. I believe Eastwood has some great products as well.

 

Used the POR15 over the weekend. Got their starter kit for 17.95 with the cleaner, surface prep and POR-15 paint. Looks great (I have a black truck). Hopefully it will hold up. Truck is 7 years old with 110K miles and that is the only rust on it.

 

I had the full Ziebart treatment 3-1/2 years ago when the truck brand new. Drilled the doors and sprayed the insides too. Three nasty, salty Wisconsin winters so far and NO rust anywhere - plus I try to keep it clean. I have had the full Ziebart with every vehicle for the last 25 years because it works and I keep vehicles 8 to 10 years.

 

I have and 05 and the drain holes have a plastic cap on them. The cap can move up and down so you can either open or close them. Now the question is why are they on there? Isn't better to leave them open or just not have them at all?