Where does Ford Transit MK6 rust?

The 2000-2006 Transit is one of the generations most prone to corrosion. Rust attacks characteristic areas: front wheel arches and wing edges, sills, especially under the right sliding door where water collects from the rail, lower edges of rear and sliding doors, body corners and the edges of the rear wheel arch openings. On RWD versions, also check leaf spring mounts and chassis rails around the rear axle.

Repair with panels or replace parts?

For local corrosion on sills and arches, ready-made repair panels are the most sensible option: shaped metal sections recreating the factory profile and welded in where the rotten part has been cut out. This is far more durable and quicker than hammering flat patches. A rotten sill under the sliding door is not just cosmetic: the lower door rail sits on it, so corrosion there ends with the door dropping and rubbing. Panels with visible perforation, such as wings, doors and bonnet, are usually cheaper to replace complete than to restore.