Ford Mustang Paint Bubbled Aluminum Panel Corrosion TSB
June 9, 2014 7:42 am Ford Problems
DenLorsTools.com Summary: Paint bubbling on Ford Mustang is a common issue. At first glance the bubbled or blistered area looks like rust bubbling the paint, but wait this hood is aluminum!
Aluminum cannot rust, but it can corrode. Corrosion under the factory paint causing paint to bubble is a very common issue. There’s even a TSB (Technical Service Bulletin) about this. The Ford Mustang is not the only vehicle affected either. The TSB includes Ford Explorer, Taurus, Expedition, Lincoln Navigator, Mercury Sable and more. Outside the 3 year 36,000 mile warranty, Ford owners are left to pay for this repair themselves. It does make Ford owner’s question their loyalty to Ford on their next new car purchase though.
Below is what the TSB # 06-25-15 has to say regarding the cause and the way to prevent this from happening again when the panel is repainted.
FORD:
2000-2007 Crown Victoria, Taurus
2005-2006 Ford GT
2005-2007 Mustang
2000-2003 Ranger
2000-2007 Expedition
2002-2007 Explorer
2004-2007 F-150
2007 Explorer Sport Trac LINCOLN:
2000-2006 Lincoln LS
2000-2007 Town Car, Navigator
MERCURY:
2000-2007 Grand Marquis, Sable
This article supersedes TSB 04-25-1 to update the vehicle model years. ISSUE:
Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel.
ACTION:
This TSB provides service tips and procedures, outlining methods to properly prepare and protect aluminum body parts from cross contamination.
BACKGROUND
Ford’s Scientific Research Laboratory has performed a number of tests on vehicle body parts returned for corrosion related concerns. Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prior to it being painted. SERVICE TIPS AND PROCEDURE
When repairing a vehicle for corrosion or collision damage, it is essential that extreme care be taken to cover and protect all aluminum parts to prevent cross metal contamination. Areas in a shop where metal work is performed should be sectioned off, using at the very least curtain walls, to prevent metal dust migration. Cross contamination can also occur through the use of metal working tools (hammers, dollys, picks, grinding wheels, etc.). Tools used for aluminum repairs should be kept separate, and not used to repair other metals. Wire brushes used on aluminum should be made of stainless steel.
NOTE:THIS PROCEDURE SHOULD ONLY BE USED ON NON-PERFORATED METAL. REVIEW WARRANTY AND POLICY MANUAL FOR VEHICLE WITH PERFORATED METAL.
NOTE:READ THIS PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE.
Corrosion should be removed by blasting. Use an aggressive blasting material, such as acrylic (salt grain size).
Use a DA sander with 180 grit paper backed abrasive. Only sand and featheredge the damaged area.
Mix and apply Ford approved epoxy primer, per the manufacturer’s label instructions. Bake at 140° F (60° C), or use an infra-red lamp for curing.
If necessary, mix and apply two-part polyester filler to a slight over crown. Allow polyester filler to cure 20-30 minutes, or mix and apply spray polyester filler two-three (2-3) coats as necessary. Allow to cure per manufacturer’s label instructions.
Hand-sand the repair area with 80 grit sandpaper to remove excess filler.
Finish-sand the repair area with 400 grit sand paper.
Mix and apply Ford approved primer/surfacer per manufacturer’s label instructions. Bake at 140° F (60° C) or use infra-red lamp for curing.
Sand the primer/surfacer with 400-600 grit to level the surface.
The next two steps are wet-on-wet. Mix and apply to hiding Ford recommended basecoat material per manufacturer’s label instructions. Allow to flash.
Mix and apply two (2) coats (2 mils minimum) of Ford approved clearcoat per manufacturer’s label instructions. Allow flash time. Finish bake at 140° F (60° C).
This entry was posted in Automotive and tagged Aluminum Panel, blistering, bubbling, Corrosion, Ford, Mustang, Paint Bubbled, TSB by admin. Bookmark the permalink.
6 THOUGHTS ON FORD MUSTANG PAINT BUBBLED ALUMINUM PANEL CORROSION TSB
Zestar Corporation on February 29, 2012 at 10:02 am said:
Ford Motor Company’s paint expert (a Ford employee) has also authored a study that has been published concerning factory paint pretreatment systems.
The study reveals the specific paint defects that occur within Ford’s factories.
Rust is listed as a contaminant within Ford’s factories paint pretreatment systems.
DennisB on February 29, 2012 at 5:59 pm said:
Rust will certainly cause the paint to bubble or blister. If there’s rust in the aluminum it would definitely have to be from something foreign, since aluminum does NOT rust (it will corrode). Corrosion or rust will cause the paint to bubble. It just shouldn’t happen on a newer car with a factory paint job.
Robert W on June 26, 2012 at 6:49 pm said:
I would like to know why there is a tsb covering 2005-2006 gts and 2005 2007mustangs but not a 2008 gt. I am on my second hood and now this one is bubbling up . Fords rust through policy says it must be rusted through for them to cover it. I think ford engineers did not test these hoods in states that use salt. The worst part for me ford denied my claim but fix prior years under that tsb. I will never ever buy a ford product again . Having an issue with your product is one thing not standing behind it is b.s.
Guy Santo on September 26, 2012 at 8:31 pm said:
This has happened to my 05 mustang and my 10 mustang. Both hoods had to be repainted or replaced. From what I know, epoxy primer is wrong! Supposed to use etching primer on aluminum. If ford knows about the problem, why do they continue to do things wrong?
DennisB on September 26, 2012 at 9:08 pm said:
Guy, I understand that some changes in production cost a lot of money. But, to fix this issue shouldn’t cost them much. This leads you to think they are OK with the issue because of additional hood sales and/or repainting once these cars are out of warranty. Perplexing to say the least.
John B on October 11, 2012 at 12:39 pm said:
I have the same bubbling problem on the rear lift gate of my 2010 Expedition. Based on the TSB, and the comments made above, it must be a failure in Ford’s panel prep process, since it is ongoing and continuous since 2000.
Jackie M. :
Date: July 7, 2014 @ 9:56 pm
My daughters 2006 mustang has this problem on her hood..Why is it just at the front edge and nowhere else? My 2005 GT is still perfect
dennisb - Auto Tool Sales :
Date: July 8, 2014 @ 7:34 am
Hello Jackie. My son’s car (which is the one pictured) is a little worse now than when I first took the picture. My guess is that the contamination caused by incorrect handling at the factory caused this. Some say it’s iron contamination from the welding, which would explain why it’s not say, in the middle of the hood. Once the corrosion starts at the weld it allows moisture in and the corrosion migrates. With the assembly line process, allowing desired uniform results, sometimes the the results, are unintended consequences. I recently considered a Mustang myself, but I thought of this issue. I’m also still very curious about the new F150 that has an ALL aluminum cab. Maybe Ford will figure out the problem – I would’ve thought they already would have. But gauging by some of the responses I’m not so sure.
Jenn :
Date: July 8, 2014 @ 12:16 pm
I also have a 2005 mustang that started bubbling on the hood 2 1/2 years ago. Now it’s getting worse! I called ford today and the lady acted like she didn’t know their was a problem that she would put my complaint in but that’s all she could do and said she was sorry! I said you mean to tell me all these complaints I see on the internet about the same problem and ford is not aware of this…. she said she doesn’t get a lot of complaints about this. she said in order to get a recall about this more people need to complain otherwise their will be no recall. I told her I was thinking about getting the 2014 mustang but forget it now will be looking to buy something different. ford will lose my business!
dennisb - Auto Tool Sales :
Date: July 8, 2014 @ 1:52 pm
Jenn, I agree. My wife mentioned buying me the 2014 50th anniversary edition because I used to drive old Mustangs and I’m gonna be fifty on my next birthday. But, one thing that crossed my mind was this hood issue. Don’t think I would risk it. I’ll keep driving my truck.
william roth :
Date: July 29, 2014 @ 10:36 pm
I leased a 2012 Mustang in May of 2011. I want to buy the car this August when the lease runs out. I just noticed the bubbling paint on the front edge of the hood. I haven’t purchased the car and don’t know if I’m going to after reading about all the problems with this corrosion problem. I haven’t discussed this with the dealer as of this date.
dennisb - Auto Tool Sales :
Date: July 30, 2014 @ 7:39 am
William, at least you don’t own the vehicle yet. Lease companies will sometimes negotiate on the purchase price. I’d get an estimate for a new hood and paint from the Ford dealer to use as a bargaining chip to have the purchase price reduced. Then you can decide if you want another Ford hood or if an aftermarket one, maybe fiberglass, would make more sense. Good Luck.
Mike :
Date: September 4, 2014 @ 4:22 pm
I have a 06 Mustang GT that I have treated like a baby. It has 48,000 miles and has never seen rain or snow since I lived in Florida. It’s hood is rusting and nobody at Ford will help…
dennisb - Auto Tool Sales :
Date: September 4, 2014 @ 4:59 pm
Mike let us know what you end up doing. Good Luck.
vincent :
Date: November 4, 2014 @ 2:59 am
That’s why I drive an Audi. I would never buy Ford, Chevrolet, GM.
dennisb - Auto Tool Sales :
Date: November 4, 2014 @ 7:35 am
Vincent, thanks for the comment. Every make has their issues. Check out how much work it is to replace an alternator on some Audi’s. Hopefully your Audi never needs one.
Scott :
Date: July 15, 2015 @ 9:24 am
I have a 2013 Ford Explorer with this same corrosion issue on my hood. I’m 1000 km over my warranty period and Ford Canada has said they cannot do anything for me. According to the ford body shop guy they fix this issue at least once per week! It’s $1000 to fix the bubbling underneath the paint that I will have to pay for myself. So frustrated and will not buy another Ford because of this. I would advise those thinking of buying a ford to consider this. This is basic science and today should not be happening; if it does at least own up to it and fix it.
dennisb - Auto Tool Sales :
Date: July 15, 2015 @ 2:44 pm
Scott I agree. What about the new all aluminum pick up truck cabs? I’ve always loved Fords. There’s a reason I now drive a Nissan.
Supercoup :
Date: July 24, 2017 @ 9:48 pm
My 2012 California Special has 41K miles on it. I noticed the paint bubbling on the leading edge of the hood about a month ago. Went to a body shop and they said if painted it would just happen again next year. The hood is made of a composition of metal and aluminum. They never sealed it properly at the factory. I buy and keep my cars. so I went and bought a fiberglass hood. It costs less than the Ford junk and at least it wont oxidize. If you break the bubble of paint you will find nothing but powder under the paint. That’s oxidation. That’s what aluminum does. Ford better find some new scientists cause the ones they have now cant scramble eggs. Ford could care less. They figure most people lease and turn them in in 2 years. The dealer paints the hood, sells the used turnin and 1 year later when it starts to lift again, its out of used car warranty. I’ve owned nothing but Fords since 1965. Never Again. I’ve also had issues with the plastic screen on my radio delaminating which ford would not consider repairing even though the damage is on the inside of the plastic. Ford has become a disgrace as an American Automobile manufacturer and I have lost all faith in them. Gonna learn to like Camaros.
dennisb - Auto Tool Sales :
Date: July 25, 2017 @ 7:24 am
Seems like all vehicles have their own particular issues. I wonder about the all aluminum Ford trucks? Seems like potential for disaster. Not to mention if you’re not careful putting things in the bed, you could poke a hole in it!