Rust on door seams

[jmpotter]

Is anyone else getting rust on the seam where the outer door skin folds in on the bottom of the door?  Both front doors are showing rust on a 2014 that is garage kept in Atlanta with less than 26k miles.

[drolds1]

That shouldn't be, especially in a southern state.  All I can think of is that the drains are plugged.  Did you check them?  Outside of that, providing there's been no bodywork, perhaps there was inadequate prep at the factory.

[R2D2]

Is anyone else getting rust on the seam where the outer door skin folds in on the bottom of the door?  Both front doors are showing rust on a 2014 that is garage kept in Atlanta with less than 26k miles.

 

Questions for you....

 

Do you normally park in the driveway or garage at home?

 

Do you have an irrigation system that is high in iron or sodium content?

 

I live in a community that the irrigation wells do have high salt content as well as iron... it does effect the the vehicles parked on driveways regularly.

 

For me, mine is rarely on the driveway overnight when the sprinklers run and the times it is I quickly take out a hose and rinse the vehicle with fresh water in the morning..

Edited March 14, 2018 by R2D2

[Billm]

I have the same issue on my 2014 on the passenger side front door. I will be bringing it by the dealer as soon as the weather warms up. We have been buried here in New England with the recent storms.

 

My vehicle is garaged and goes through a car wash with underbody spray wash on a regular basis (I have an unlimited monthly pass).

[jmpotter]

garage kept in Atlanta = not parked outside overnight.

 

Never driven in the snow.

[Izzy3906]

Looks like a common thing on the 2014 MKZ, my front driver side is going thru the same situation. 

[Dino]

My 2014 does not have this problem, Texas car, now in Ohio, that is not driven in bad weather.

 

Now that I have seen yours and hearing about others with the same issue, I am going to put some seam sealer on mine.

I will tape it off and use some black seam sealer I have to give it a nice neat and tidy appearance.

I plan on keeping this car for awhile.

[DeviLSh]

Just found this on my MKZ today, front passenger door. but mine is on the vertical section of the door, bottoms look great. Lifting paint, and some surface rust has began. 

Warranty booklet says 5 years for paint/corrosion, looks like I could be out of luck. My CPO coverage also excludes corrosion. Gah 

[TomV]

The rust starts from the INSIDE of the door. Gravity causes moisture, dirt, salt, etc. to collects there and bubble out.

If Ford/Lincoln would coat the Steel, before they stamped and folded it together, it would last a lot longer. From what I can tell on my last car, all folded metal seems are bare metal underneath. The paint/corrosion coatings don't penetrate into the seams.

If you could pour or spray some sort of rust converting agent into the inner door frame, it might work it's way down and hopefully stop or slow the rust process. 

[chrisinky]

I have this on my passenger door.  I noticed that when the door is shut the bottom door drain seals can't drain.  My kids get in left/right rear doors.  My oldest now sits up front so he's in and out more up front.  As someone else mentioned this is from the inside out.  I used a dremel tool and took it down to bare metal and recoated it.  It appears to me it's below the seam sealer at the bottom of the door, if thats the case, this is just hoping it won't come back....

[tiktok4321]

Oh dear.  This is happening on my '13.  This isn't good.  Car only has 50k miles.  I thought most US cars has 100,000 rust coverage.  This sucks.

[drolds1]

Ford's Corrosion coverage is for 5 years, unlimited mileage.  Only outer body panels are covered for perforation in that period.

[Viking]

But there has to be perforation, and it has to be from the inside out, in their judgement.  I have gone through this several times with Ford dealers.  My solution has been to Krown coat my vehicles from new.  I have a 2004 Ford F250 Superduty diesel with absolutely no rust aside from the surface frame rust that comes as soon as the wax coating peels off.  I have had Ford vehicles since the 1960s and this has always been a problem.  Newer GMC and Cheverolet trucks are now having this same problem where I live, but there is a lot of calcium chloride and salt used here in winter, which exacerbates the problem.  Krown or Rust Check, or other undercoats which "creep" are about the only solution that really works in my neighborhood.  We just have to accept the mess that comes with having an oily substance picking up dirt and soot.

[Andrew H]

I have this same rust problem on the rear driver side door door seam.

2017 MKZ 3.0t Reserve

30,300 miles

[shtaka]

Mines going in this week to have all 4 doors done.

[Zondedo]

In Michigan and the other rust belt states rust proofing has been very common since the late 70s.  I’m not sure I’m ready to take that step but I’m considering drilling some access holes in my doors and injecting oil into them to penetrate the seams.  It’s worked very well for me in the past and has saved a lot of my vehicles.  I wonder if this is also an issue on the Fusion?

[leftoverture]

2 hours ago, Zondedo said:

In Michigan and the other rust belt states rust proofing has been very common since the late 70s.  I’m not sure I’m ready to take that step but I’m considering drilling some access holes in my doors and injecting oil into them to penetrate the seams.  It’s worked very well for me in the past and has saved a lot of my vehicles.  I wonder if this is also an issue on the Fusion?

Indeed.  Here in Minnesota we would scarcely notice such minor rust.  It's just expected.  40 years ago cars rusted so fast you had to check for rust on anything older than 6 months. 

[Multitask]

A warranty for rust does not mean it will not rust... it just means that it is covered for repair if it does.  ?

[TomV]

Any exterior paint touch-up by the dealer or autobody shop is NOT going to stop the rust.

 

I would recommend getting some of that rust converting spray to treat the rust on the inside. Use a plastic spray tube (like the red tube from a WD40 can) and shoot it into the door interior from the drain holes. Then at a later date, spray some sealer paint or cover coating into the door to coat the converted rust. I'm going to do that to mine as preventative maintenance. 

[Izzy3906]

I have a 2014 MKZ and all 4 doors have rust on the seams.

Took it to a shop for repairs and this is how it looks like after taking a piece off the seam.

He is going to fix it but he told me that in the future I might have to replace the doors.

When that happens I'll just trade it in.

 

 

 

[Izzy3906]

He finished all four doors and this is how it came out much better now than with all that rust.