Why Do Ford Hoods Corrode So Easily?

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#body #corrosion #exterior
A large patch of hood paint is missing right above the grille, revealing the hood's bare metal.

Hood corrosion on a 2003 Explorer. Image source

2000-2007 Ford, Lincoln and Mercury vehicle owners are learning that Ford knew about corrosion issues during the assembly process, but failed to correct the problem and sold the vehicles anyway. And it's rightfully ticking them off.

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 corrosion.[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.[1:1]

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?

  1. NYTimes: Judge Allows Suit Over Aluminum Corrosion in Fords to Move Forward ↩︎ ↩︎

Lawsuits Regarding This Problem

Lawsuits about this problem have already been filed in court. Many times these are class-action suits that look to cover a group of owners in a particular area. Click on the lawsuit for more information and to see if you're eligible to receive any potential settlements.

  • Dismissed

    William Mickens and Mark Solomon v. Ford Motor Company

    1. Dismissed

      The judge ruled any claims against Ford for damages to Mustangs before the 2005 model year are false because Ford could not have had any knowledge that galvanic corrosion of aluminum hoods would occur in the 2000-04 models. Those cars did not have aluminum hoods but had hoods made of sheet molded compound.

    2. Proceed

      A federal judge says that a class action suit claiming corrosion on aluminum body panels has reduced the value of millions of cars and trucks made by Ford should proceed with depositions being taken this year.

    Class Vehicles
    • 2002-2009 Mustang
    New Jersey
  • Dismissed

    Cavette, et al., v. Ford Motor Company

    1. Dismissed

      Court documents don't go into much detail, but the plaintiffs say their claims in this matter pending against Ford Motor Co. (Defendant) have been resolved to the satisfaction of Plaintiffs and Defendant.

    2. Case Filed

      A Ford Explorer hood rust recall allegedly should have been ordered long ago, or so says a plaintiff who filed a proposed class action lawsuit about aluminum hoods.

    Class Vehicles
    • 2000-2017 Explorer

Generations Where This Problem Has Been Reported

This problem has popped up in the following Ford generations.

Most years within a generation share the same parts and manufacturing process. You can also expect them to share the same problems. So while it may not be a problem in every year yet, it's worth looking out for.

OK, Now What?

Maybe you've experienced this problem. Maybe you're concerned you will soon. Whatever the reason, here's a handful of things you can do to make sure it gets the attention it deserves.

  1. File Your Complaint

    CarComplaints.com 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. Notify CAS

    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. Report a Safety Concern

    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