He is correct about sealing the third brake light gasket. Other mfg's have the same problem.

 

I recently purchased a 2003 Chevy Z71 Ext Cab 4 door with rusted rockers and cab corners thinking this would be something that would be a fairly straight forward repair. Seems I am wrong. Most body shops in my area won't touch it. The comment is "this is a common problem with ALL Chevy/GM trucks and we don't do rust repair". The two smaller shops I found willing to discuss a repair estimate $5,000 to complete the work. That to me is a "chunk of change." The issue doesn't seem limited to this year and model; I see similar rusted rockers, cab corners and fender arches on many Chevy and GM trucks much newer than mine. My point is, isn't it about time GM does something to correct this? Back in the 70's Chrysler/Plymouth had to replace the front fenders on many of their Volare models because of rust through--I know because I had one at the time. Maybe this could be precedence for some relief for Chevy/GM owners facing this "common problem". Has anyone heard of GM taking any responsibility for this continuing issue on existing trucks or steps to "fix" is on new models?

 

well that sucks just got my rockers and cab corners done for $2500 and not by a half ass body shop ether

 

There are body drains all over vehicles. These need to be removed and washed out once a year. You wouldn't believe how much dirt, sand and road grime is stuck inside these pockets. Every single pocket on my 1998 sierra was filled as high as it could be with it. I discovered this while repairing all these problem areas.

I don't think it's a design flaw because these areas need to breath. I think it's a maintenance issue.

Al

 

Re: Rusted rockers, cab corners and wheel arches being a maintenance issue... if this is truly owner required maintenance I wonder why it isn't called out in the Owners Manual and part of the "recommended" regular service schedule (similar to oil changes, tire rotation, and etc.) with information on how to access the drains and instructions on how to "flush" them (maybe it should be). I can't remember a time when a service provider or dealer service technician suggested this maintenance for any vehicle I've ever owned--I've made a mental note to ask in the future. That said... has anyone used the cosmetic cover-ups available to "hide" the issue? If so, how did that work for you?

 

This info is definitely not in any scheduled maintenance whatsoever. I learned this on my own while doing body work exactly like @BornAgainBiker55 suggested and by watching our work fleet vehicles being oil sprayed. The reason my 97 Burb is in such great shape for its age is because it spent most of its life in Texas and once it came to Ontario Canada it was always rust proofed with oil sprays. No I dont do the oil spray because I dont like the oil mess, instead I pop out the body drains, remove tail lights/headlights and wash out all the **** simply with a garden hose and plain water, leave it in the sun until its dry and reassemble. Ask a highley recommended body shop these questions and they should tell you the same info... the panels rust from the inside out.

Al

 

I did a garage fix for my rust around the rear wheel wells. First removed the damaged material and put rust inhibitor on. Then Bondo and paint. Then hid my not professional work with a fender flare. Looks OK but the truck's a 2003, no reason to put a ton of money into it other than to prevent the cancer from spreading.

 

Ok, now that you know, you have a weekend project. Your starting with new metal, get it protected.
Get into the bed and remove the light. Maybe you can fine a new gasket, maybe not; but you can make one.
Get some gasket material, trace the old gasket and cut out the new one.
Run a small bead of silicone on both side and reassemble.
Then go to the inside. Remove the interior trim panels to expose the new metal.
Get some metal protecting paint and paint everything.
You might have to get under the truck to paint the back side of the rockers.