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23 replies to this topic

#21 OFFLINE   rjd75


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Posted 02 November 2017 - 01:18 PM

Amazing that cheap aluminum siding on a house doesn't have these problems, but an expensive SUV does..

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#22 OFFLINE   fordtech1


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Posted 02 November 2017 - 06:38 PM

Amazing that cheap aluminum siding on a house doesn't have these problems, but an expensive SUV does..

Agreed. However your house doesn't drive 70mph on the interstate subject to bugs and road rash.

#23 OFFLINE   HarryTitus


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Posted 12 November 2017 - 04:54 PM

A trusted Ford expert told me a few months ago that they finally figured out the problem. According to him, they stamped steel panels on the same dies as the aluminum panels, leaving just a molecular trace of ferrous material as a residual on the dies. When the aluminum panels are  then stamped, the residue transfers to the aluminum. The dissimilar metals then corrode. I know, sounds far fetched, but they have since quit using the dies for steel parts and the problem is supposed to be solved.


By the way, my 2005 Expedition had some small corrosion starting to show about two years ago. It was never garaged, ran Ohio roads in the winter, and only had a few small corrosion spots when I traded it in on the new Super Duty two months ago...however, the Rocker panels (steel) were completely rusted off all the way into and past the door seals. Compared to the rocker panels those aluminum parts held up pretty good I'd say!



#24 ONLINE   dennis48755


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Posted 17 November 2017 - 11:39 AM

Not sure what you call it bump/dent guard/shield, but the gen3 Expeditions had a 9 inch vinyl trim layer around the bottom body that would appear to protect the body from dents.


I don't see this in the new Gen 4, is the lower aluminum body exposed to dents especially from opening the door against a gas pump cement post for example? Or is it there and just not apparent from the photos.



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