Ford's Problem with Aluminum Hood Corrosion

Ford Aluminum Hood Corrosion
Class action lawsuit claims Ford's knew about rust problem

Cars are prone to rust, unfortunately that's just the way it is. This is especially true for those who live in rust belt states where salt is used to clear ice from roads. We can fight the onslaught with regular washes and waxing ... unless you own one of these Ford hoods. Then it's inevitible.

Why Do Ford Aluminum Hoods Rust So Easily?

When buying a car, it's reasonable to expect the manufacturer to do the same. Cars are, afterall, one of our largest investments. So when it comes out that a manufacturer might have known about a corrosion issue during the assembly process, but failed to do anything about it and sold those vehicles anyway, it rightfully ticks consumers off.

That's exactly the situation owners of 2000-2007 Ford, Lincoln and Mercury vehicle owners find themselves in.

Reports of Ford Hood Corrosion on

New reports of corrosion related issues from Ford owners are coming into weekly. As of March 2013 here's how the data breaks down:

Ford Owner Complaints about Aluminum Corossion
Model Complaints
2002-2009 Ford Mustang 28
2002-2006 Ford Explorer 172
2001-2007 Ford F-150 28
2001-2005 Ford Explorer Trac 17
2004-2005 Mercury Mountaineer 6
2001-2007 Ford Expedition 11
Other Ford Models 15

Class Action Lawsuit for Ford's Aluminum Hood Rust

A class action lawsuit filed in the United States District Court in New Jersey claims that Ford used aluminum hoods but failed to properly insulate them from "old iron-based connecting and supporting parts," despite knowing that "would give rise to galvanic coupling" and corrision.[1]

It goes on to say that the automaker went on to conceal this inevitable problem from buyers, drastically reducing the long-term value of their vehicles.

Ford not only denies this claim, but says the suit is so lacking in merit that it should be dismissed. Last fall, Judge Kevin McNulty granted only part of Ford's request, dismissing one of three counts, allowing the case to continue.[1]

How Much Did Ford Know About the Problem?

Ford can deny concealing the problem until the cows come home, but actions speak louder than words. In 2004 the manufacturer sent dealers a technical service bulletin (TSB) about bubbling and blistering under the paint on aluminum body panels due to "iron contamination of the aluminum panel".

The TSB goes on to say that "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."

Hey Ford, what was that about not knowing this was an issue?

Actions You Can Take

The judge has yet to rule on if this class action lawsuit covers all owners or not, which is a huge distinction given the millions of Ford vehicles on the road. Depositions in the case will begin this year.

Elizabeth Weigandt, a Ford spokeswoman, says, “Ford cannot comment on pending litigation, however, the company is absolutely committed to top quality and customer satisfaction. We recommend that customers with any questions on our products either contact their dealer directly or visit Owner Support at”

Next Steps

This step is crucial, don't just complain on forums! The sites below will actively manage your complaints and turn them into useful statistics. Both and the CAS will report dangerous trends to the authorities and are often called upon by law firms for help with Class Action lawsuits. Make sure to file your complaint on all three sites, we can't stress that enough.

  1. Step 1: File Your Complaint at is a free site dedicated to uncovering problem trends and informing owners about potential issues with their cars. Major class action law firms use this data when researching cases. Add a Complaint

  2. Step 2: Notify the Center for Auto Safety

    The Center for Auto Safety (CAS) is a pro-consumer organization that researches auto safety issues & often compels the US government to do the right thing through lobbying & lawsuits. Notify the CAS

  3. Step 3: Report a Safety Concern to NHTSA

    The National Highway Traffic Safety Administration (NHTSA) is the US agency with the authority to conduct vehicle defect investigations & force recalls. Their focus is on safety-related issues. Report to NHTSA


Share Your Complaint

Add Your Complaint

Join thousands of frustrated car owners who have voiced their opinion and notified other consumers of issues at

Ford Customer Relationship Center

P.O. Box 6248 Dearborn MI 48126