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aluminum corrosion- any progress?


ford4v429

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  • 1 month later...

a couple months, 176 views, not one comment?

 

http://www.google.com/search?hl=en&redir_esc=&client=ms-android-verizon&source=android-launcher-widget&v=133247963&qsubts=1347463588079&action=devloc&q=ford+alum+hood+corrosion&v=133247963

 

Its a real problem with all ford aluminum hoods- i hope ford has a ear to the ground on this, if the big wigs are hearing its a uncommon issue or something, whoever is telling them that needs to go... I hope ford continues to do well in these tough economic times, but long term ignoring quality issues is not acceptable-this is the kind of thing that can make customers jump ship, no matter how otherwise good a product might be.

 

Nobody wants to be making payments still on a car with the hood all blistered up, and find out corrosion warranty most often wont cover it (as its not corroded thru- just looks like shit).

 

Fords got some great products out there, but reading about '11/ '12 mustangs with the paint blistering off the hood (as has been a common issue since 2004) is kinda upsetting :(

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  • 3 months later...
  • 2 weeks later...

I have a 2005 Freestlye, and 2006 Mustang and both have this problem. I wish it was something that would be taken care of. Hate looking at the crappy bubbling paint. Ruins two otherwise great cars.

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  • 2 months later...

Wow, looking at some of the threads linked, I'm surprised Ford sells any Mustangs. It's complete BS they won't cover this outside of the 3yr/36K mile warranty. My room mate's 2010 Mustang has been riddled with small little quality issues...at 35K miles. That being said though, he has a 2010 GT with the premium package (HIDs, etc) and the track pack and wow, that is one machine. The clutch on that car is the best clutch I have ever used. And driven nicely, it will get 23+ MPG.

 

The only complaints he has is the rather low quality of the interior and the small gas tank. Other than that, he absolutely loves it.

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My dodge had this problem when I bought it- after 1 year it started to bubble under the paint. I had read about it on forums too and even some nightmare stories about how the dealer won't cover it - blah blah blah. I went to my dealer and he said he's seen it before and even explained how it was a bad batch of hoods with bad seams that weren't sealed properly. Anyway - they replaced it no problem and never had another problem. Sure hope Ford gets a clue and gets the issue resolved.

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  • 1 year later...

took a pick/razor blade /scraper to my undriven, 4 mile, only been wet twice 09's bubbled up hood underside...two corrosion blisters about the size of a quarter. Hope I can stop it where its at, both propagated from the tiny bubbles it had new, rest still looks fair

also got after the wifes 07 (already replaced the hood on my 06 years ago) hers has 4 big blisters and most of the lip(luckily hasnt bubbled to the visible part, but another 1/16 of a inch it will)

sorry ford/AAI paint/prep guys, but your hood prep/process/paint just plain sucks. shitty job guys, shitty job...

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  • 3 weeks later...

sorry ford/AAI paint/prep guys, but your hood prep/process/paint just plain sucks. shitty job guys, shitty job...

 

 

Well as far as I know its not a Ford prep problem, I had a front end accident in September 2007 on my 2006 Mustang GT and the hood was replaced on it by a body shop and I just noticed the bubbling under the hood this past weekend when I washed the car.

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Well as far as I know its not a Ford prep problem, I had a front end accident in September 2007 on my 2006 Mustang GT and the hood was replaced on it by a body shop and I just noticed the bubbling under the hood this past weekend when I washed the car.

Aluminum is very sensitive to steel dust. Ford is telling dealerships that they basically need a whole new body shop with separate tools if they want to be "certified" to repair the aluminum F150. I would not be surprised if you pop one of those paint bubbles and inspect underneath with a magnifying glass if you see some minute orange specs. Iron oxide - RUST !

 

 

I can't find the data at the moment, but the aluminum used in the F150 is "new". It is a new alloy developed by Alcoa, originally for government military vehicles. On top of that it has a unique "pickling"/coating on it to reduce corrosion and make paint stick better.

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  • 2 weeks later...

 

 

Well as far as I know its not a Ford prep problem, I had a front end accident in September 2007 on my 2006 Mustang GT and the hood was replaced on it by a body shop and I just noticed the bubbling under the hood this past weekend when I washed the car.

 

I gotta respectfully disagree- did you see the pics in post #4? those were brand new Mustangs at the 2014 international auto show. the blue boss 302 had dirt/jagged edges and that little piece of wire sticking out of the hood seam. the silver one had nasty bubbling- yeah some might say 'mastic/ecoat boilout/whatever' but its NOT metal, its NOT primer and it IS under the paint- and it looks like shit... these hoods are failing to paint bubbling off every day- just Google Ford aluminum hood bubbling- its a big problem, has been since 2004 on mustangs, and is still there a decade into it. if ford tries to say otherwise- well, a picture says a thousand words.

 

with the pricetags on these cars, sorry...I gotta stick by my original opinion to whoever passed this into the paint booth and on to a dealer/customer: shitty job guys :(

 

either line employees realize the hoods have crap under the hoods before they roll into paint, or they dont know the hoods have crap under the hoods before they roll into paint- either way they are NOT doing their job properly.

 

either management is aware of the problem, or management is unaware of the problem- either way they aren't doing their part.

 

in my opinion, the lowly Hyundai's at the auto show have had consistently the best fit/finish of all the manufacturers represented, even more exotic brands had minor 'coulda been better' issues with seam sealer/hems/etc... I think GM trucks by far have the WORST panel assembly- look at the rear wheel arch reflections on any Silverado/Colorado the last few years, you can see dings/weld distortion in all of them... but by far the most glaring 'oops' at the auto shows in 13 and 14 has been Ford hoods- especially the AAI assembled mustangs, but also the Taurus/fiesta... the taurus apparently has jig/fixturing issues as all had either wrinkled, chipped left front hood corners, and/or adhered-pulled away paint on the left front corners or tip of fender above headlight- like was cleared too heavily with hood shut and glued hood to fender- half had fender tip-to-hood adhesion problems...think those are made in Hermasillo?

 

just when you see the pricetags, the incredible performance/mileage/mechanical reliability, fancy interiors of any new model, just gotta wonder why Ford is so lax in their paint inspection, and why GM is doing such lousy sheetmetal work on trucks. Worse, you gotta wonder why its there the next year, and the next year...

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seven years later though... the 2014s pictured were brand new Fords with dirt and 'stuff' under the paint... I understand where you are coming from though, the problem likely still resides with the hood assembly itself- Ford said 'iron contamination' years ago, but its still happening (assume they corrected/eliminated that), where I still think its due to a sharp edge crimped against a panel with no seam sealer/no way to seal between the layers...some new mustangs (boss 302/possibly others) DID have seam sealer applied, but as the pictures show, the sealer was applied improperly, missing the edges leaving gaps for water to still get in.

 

I still worry if the all aluminum F150 is assembled with similar care to the mustang aluminum hood (unclean before paint/seam sealer misapplied leaving seams exposed) we will be seeing issues on the '15 trucks within a year or two. if the current process flaws havent been addressed a decade into the model, I have little confidence they wont appear elsewhere.

 

6061 has been around since the 30's, wondering (hoping) some other crap alloy was used on Mustang... is there anyone here at ford tha can find out the actual '15 alloy (reports say '6000 series', but gotta assume its good old 6061) and what alloy was used on 2005-2014 mustangs and others? really doubt junky 2024 alloy woulda been used, but who knows?

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a buddy at work has a 'beater' Miata he drives year round, not a trace of blistering on his either... seems like some trucks/models it started in the late 90s, but others never had it at all- Mustang from 2005-current have been terrible though- this is what makes me believe its more of a line/process issue than a materials issue...if Ford used 6061 for some/2024 for others, that would explain a lot- but again, why wouldnt they have simply corrected the alloy at the next part revision?

 

on the dirt/contamination thing, I really still believe it is undeniably poor prep- when you can see dirt/burrs/wires sticking out of the paint under the hood of a brand new high-end Boss302, its painfully obvious the paint line inspection never looked or just ignored it... if the dirt wasnt wiped off, whats the odds any oils were?

 

again though, my biggest beef is brand new cars going out the door after final looked them over and noone saw these hoods- or it was deemed acceptable. if acceptable, the QA decision making guys need canned, if unacceptable, the line guys do- either way these brand new cars with screwed up paint, on a part with a well documented failure trend is just pathetic.

 

look at ANY hyundai and 99% of the toyotas at the next auto show, look closely at the hood/door hems, roof/bodyside seams, etc, then go look at Ford- Hyundai is consistently perfect, ford is the worst of all brands ive looked at...great products, but front and center the paint is sloppy, and certain models, the paint will fail in areas that should be the LAST places you'd see corrosion on a car.

 

my 4 mile 2009 mustang has only been exposed to water twice in the last 6 years, the raw aluminum engine block doesnt show any of the typical corrosion that occurs on bare cast aluminum, but the hood paint started bubbling up underneath with white powdery corrosion this fall?

 

somewhere along the line, Ford has dropped the ball for a decade now. if the new F150 shares whatevever process flaw is causing 2005-2014 Mustang hood failures (material type/prep procedures/tooling/sealing/painting) they will deserve the results. Either they know how to fix it (and did nothing) or they dont think its a issue (long as they arent typically noticed till warranty expires).

 

the auto show pics i got this year included VINs which ive posted several places- eventually carfax or something will pick them up- in a few years when these vehicles are denied warranty (99.9% of folks dont even look underhood anymore- let alone inspect the hood seams- until the surface bubbles up and they find it propagated from the underside) and someone stumbles onto pics of their new car sitting at the auto show with the problem...

Edited by ford4v429
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