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Guest Message by DevFuse

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FORDS ALUMINUM BODY SECRET:


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15 replies to this topic

#1 OFFLINE   Craig Morton

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Posted 06 March 2017 - 08:36 PM

Our 2015 Ford Expedition with 20,000 miles in California has Aluminum Corrosion on the front hood and rear hatch door. Ford has known about this problem since the year 2000 and has done nothing about it, documented in Technical Service Bulletin TSB 16-0028. Dealerships are aware, but do not disclose the factory defect prior to sale, which is Fraud.

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#2 OFFLINE   theoldwizard

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Posted 07 March 2017 - 07:03 AM

First, the TSB was not released until 2016.

 

Second, a TSB only recommends the best repair procedure.

 

Third, no one at a dealership is responsible for reading every TSB and and disseminating the information to sales reps.

 

 

That TSB applies to 10's of thousands of vehicle.



#3 ONLINE   twintornados

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Posted 07 March 2017 - 07:23 AM

It is not really a "secret" if they are publishing a TSB about it.....


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#4 OFFLINE   buddysystem

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Posted 07 March 2017 - 10:11 AM

What's different between these corrosion related issues and the new F150?  Are there any early indicators that it may still be a problem or has the new F150 paint process licked the problem?  Too early?


Past Fords:
1997 Explorer XLT (hers)
1994 Mustang Cobra
1989 Probe GT
1988 Festiva (hers)
1986 Mustang GT
Current:
2005 GMC Yukon XL

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#5 OFFLINE   theoldwizard

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Posted 07 March 2017 - 12:54 PM

Well, unless someone from inside the company comes forth and explains the "root cause" of the problem (likely salt water caused corrosion) we will never know.  It is known that very small amounts of cross-contamination (iron dust) on aluminum prior to priming will quickly cause corrosion.  It is also know that the best anti-corrosion primer for aluminum is zinc chromate based (typically a yellow-green color) and NOT the standard steel auto primer.
 
We do know that Ford is using a new aluminum alloy on the F-series (and likely the Expedition/Navigator) that had NOT been used for auto body panels and is has a new Alco patented treatment (pre-primer). that is applied (IIRC) before the metal is shipped to Ford.
 
 
 
In my own personal "quest", I have spoken to several different professional "bump and paint" folks  Most will gladly take your money and offer no warranty to sand, fill and paint.  Some will recommend replacing the entire panel ($$$) !  One or two go to elaborate lengths of complete removing all trim and components off the door.hatch, removing all paint and primer INCLUDING ON THE INSIDE !! Filling low spots is followed by priming with zinc chromate primer, regular primer, base coat, clear coat and complete re-assembly (also $$$).

Edited by theoldwizard, 08 March 2017 - 07:31 AM.


#6 OFFLINE   akirby

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Posted 07 March 2017 - 12:57 PM

I thought part of the problem is that some parts like Mustang hoods came from suppliers already painted and/or primed.



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#7 OFFLINE   theoldwizard

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Posted 07 March 2017 - 01:01 PM

Duplicate

Edited by theoldwizard, 07 March 2017 - 01:06 PM.


#8 OFFLINE   theoldwizard

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Posted 07 March 2017 - 01:09 PM

I thought part of the problem is that some parts like Mustang hoods came from suppliers already painted and/or primed.

I have often wondered about this.  Sounds feasible, as hopefully Ford would be aware of the likelihood of cross contamination if the panels were stamped sides-by-side with steel panels.  I still believe that improper preparation (Were tha panels proper cleaned after assembly ?  Did they use zinc chromate primer ?) is the root cause.



#9 ONLINE   fuzzymoomoo

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Posted 07 March 2017 - 01:50 PM

I thought part of the problem is that some parts like Mustang hoods came from suppliers already painted and/or primed.

that may have used to have been the case with the Mustang at least, but the current Mustang hoods are entirely handled by FRAP from stamping all the way to the end of final assembly.

What? What happened?


#10 OFFLINE   silvrsvt

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Posted 08 March 2017 - 12:15 PM

I did about 15K worth of front end damage to my Mustang about a year after I got it when I rear ended someone. The hood was replaced and painted by the body shop and I still have bubbling paint under the hood where the creases are. 

 

I don't think this is a factory issue, unless the hood supplier is accidentally contaminating them somehow. 


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#11 ONLINE   fuzzymoomoo

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Posted 08 March 2017 - 01:32 PM

I did about 15K worth of front end damage to my Mustang about a year after I got it when I rear ended someone. The hood was replaced and painted by the body shop and I still have bubbling paint under the hood where the creases are. 
 
I don't think this is a factory issue, unless the hood supplier is accidentally contaminating them somehow. 

MY2015 onwards for sure the supplier is FRAP

What? What happened?


#12 OFFLINE   theoldwizard

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Posted 09 March 2017 - 07:49 AM

I did about 15K worth of front end damage to my Mustang about a year after I got it when I rear ended someone. The hood was replaced and painted by the body shop and I still have bubbling paint under the hood where the creases are. 

 

I don't think this is a factory issue, unless the hood supplier is accidentally contaminating them somehow. 

Did the crash parts have zinc chromate primer under the standard primer ?

 

Proper cleaning of the bare metal, after the part is assembled, and priming are key to preventing aluminum oxidation.



#13 OFFLINE   silvrsvt

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Posted 09 March 2017 - 11:50 AM

Did the crash parts have zinc chromate primer under the standard primer ?

 

Proper cleaning of the bare metal, after the part is assembled, and priming are key to preventing aluminum oxidation.

 

No clue to be honest with you....this was on my 2006


"Hell, there are no rules here-- we're trying to accomplish something."
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Ford Products owned though the years:
1986 Escort GT Race Red
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199923.png
 
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#14 OFFLINE   blwnsmoke

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Posted 11 March 2017 - 09:33 AM

Same thing going on with the Aluminum hood on the Explorers.. paint bubbling and flaking off on the front lip (mostly under the front lip of the hood).  Mine has all the bubbles but hasn't flaked off so I haven't done anything about it.

 

My understanding was that the aluminum parts were being dipped along with the rest of the vehicle on a universal coating and now the aluminum parts are being dipped by themselves with a better treatment (as mentioned above).

 

Only time will tell but hoping that this has been resolved as this could be disastrous with Ford on the Fseries if this becomes an issue.



#15 OFFLINE   tbone

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Posted 13 March 2017 - 09:39 AM

 
Only time will tell but hoping that this has been resolved as this could be disastrous with Ford on the Fseries if this becomes an issue.


I'm hoping you're right as well. I had bubbles on the rear tailgate of my 07 Expedition. I have seen my fair share of bubbles and peeling on those aluminum parts on other Fords as well. As a matter of fact, I followed an Expedition to work this morning that had a really bad looking tailgate. I would like to think they have this figured out now, considering the major implications it has for the company.

#16 OFFLINE   theoldwizard

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Posted 17 March 2017 - 08:23 AM

This is now covered.  From the 2016MY Warranty Guide, page 11.
 

If aluminum body panels have corrosion or rust damage, and the damage is not the result of abnormal usage, vehicle accident, customer actions and/or extreme environmental conditions, the corrosion or rust damage repairs are covered for 5 years, unlimited miles.

 
 


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