Howdy, Stranger!

It looks like you're new here. If you want to get involved, click one of these buttons!

Ford Expedition Rust and Paint Problems



  • ricardopricardop Posts: 2
    I have a 2000 Eddie Bauer and I had problems with rust on the undercarriage only a few years after purchasing it.

    Now the car has a rust on the roof produced by the rust and the bottom of the back passenger side door is rusting to piesces.

    Anybody has similar issues?
  • knotaknota Posts: 1
    I have a 2003 F-150 with paint blistering on the edge of the hood. Ford knows they have a problem, just trying to keep it to themselves. I found out today by searching the internet that they issued a technical service bulletin on December 27, 2004 titled Aluminum Corrosion, number 04-25-1. The issue as described in the bulletin: "Some Vehicles may exhibit bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel." The bulletin goes on to say, "Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prio to painting."

    It covers most 2000 to 2004 larger cars, suv's and pick-ups including the expedition, explorer and f-150.

    Now you know the problems, a latent manufacturing defect. So far no luck in getting for to fix the problem. They say their corrosion warranty won't cover it unless the metal is perforated, even though they label the service bulletin as aluminum corrosion.
  • corinnamcorinnam Posts: 1
    I feel your pain. We have a 2003 Expedition and it's totally bubbling and peeling on the back gate. Ford says since it's not corrosion and it's past the 5 year warranty, they will pitch in $400 to have it re-painted. The body shop said they have repainted these, just to have it bubble off soon again. This is very frustrating and I swear I'll never buy another Ford Product again.
  • Hi - I have a 2004 Escape I bought new and I have paint lifting off down to the primer on the rear lift gate at the top edge and it's beginning on the hood now too. Ford is stonewalling me and is refusing to help fix this paint problem. I also have doors corroding from the inside out on all four but the drivers side is worst. They only are saying they are willing to fix the one door. No help on paint! This sounds like enough for a group of people to take paint issues to Ford for a class action.
  • mschmalmschmal Posts: 1,757
    You people need to understand that the only protection you get when you buy a car is lemon law and the car warranty. If something is not covered by warranty, then you don't have recourse against Ford.

    Now if you feel that Ford is wrongly denying warranty coverage for a problem that SHOULD be covered then you have something to talk about.
  • Iam having the same problem with my 2003 F150 the dealer repainted the hood about a year ago but its back
  • ricardop: I have a 2000 EB too and had it at the dealer for regular 75K service. They are telling me I need to do $3,000 of repairs, mostly due to rust. I cannot believe this.

    I don't live in a region where they use salt on the roads and I park in a garage every night. I'm thinking there is a defect with the vehicle. Would like to find out how many others are having the problem to determine if Ford has some responsibility beyond warranty.

    Did you end up doing repairs? Did you spend a lot? Thanks.
  • At the end of the story I ended up repainting the vehicle and in the process we founded multiple areas with rust. Mud guard, roof, hood, ens of doors ect...

    I think if enough people get together there is room for a class action....they know they bought a bad batch of steel for this vehicle but they are hiding behind the warranty time issue.
  • buzzz1buzzz1 Posts: 42
    Where is the rust and why does it cost 3,000?

    The truck is supposed to be covered by a 5 year rust through warranty.
  • The rust was mostly around the wheels, and on some transmission parts. They had to fix:

    - Front rotors and front hubs (they couldn't take the rotors off, they were "rusted onto the hubs" so had to change the hubs too)
    - Rear axle seals. In doing that, they noticed the backing plates were rusted and needed to be changed.
    - Transfer case output seal and slip yoke and U-joint (rusted)
    - Rear rotors: Had to be changed because the park brake, which is mounted inside the rotors, was in very poor shape (not sure if this was rust-related though).

    A few other non-rust maintenance items were performed as well.

    The 5 year rust warranty doesn't apply, it's a 2000 model.
  • laf7laf7 Posts: 2
    I have a 2001 XLT and have problems with rust underneath also. The parking brake was so rusted that it broke into pieces jamming up the rear wheel and had to be removed. Now my rotors are so rusted in the rear they have to be replaced. I only have 55,313 miles on it and it has always been in the garage and kept clean. My sway bar in the front end is also broke on both sides and needs replaced. So much for "Built Ford tough" I won't buy another Ford product.
  • mschmalmschmal Posts: 1,757
    Just how old does a truck have to be before its allowed to rust?

    Did you always do an undercarriage clean after driving on salt covered roads?

  • To be saying this you must either be a Ford representative or have very very low standards (perhaps you've only driven american lemons?)

    I can't imagine any consumer accepting rust on a $40,000 vehicle after 8 years and 75,000 miles, at a time when salt is not used on roads anymore.

    I have a 1997 Honda CRV that's been driven in the same region and weather conditions, has 140,000 Miles, and doesn't have a spot of rust.
  • charlibobcharlibob Posts: 1
    I have a 2001 F150 with very extensive rust on the roof... to the point of going clear through the metal in places. This only started appearing early this year. There is only 48,000 on it, although I guess that isn't a factor. I don't live in an area where salt is used on the road.

    I just got the stock answer from Ford that rust is only covered for five years, and that there was no history of complaints about rusting on this line of vehicles. I got two estimates from body shops. One would agree to cut out the dollar size rust spots, there are 8 of them, weld new patches in place, do corrosion treatment, and repaint the top for $1600. The other shop refused to do patches, saying that they would not be satisfactory, and wanted $3000 to replace the roof.

    From reading through this thread, it seems Ford has a problem with the rust issue that needs to be addressed, even if out of warranty. Anyone else have some ideas.
  • wvgasguywvgasguy Posts: 1,405
    I can understand being upset with the rust mentioned by the previous poster under his vehicle. I can't see however how rust on the roof "snuck up" on you. Dollar sized rust spots going through the metal in less than a year??? Surely there was some bubbled paint or small spots showing up earlier. Do you wax your vehicle?
  • I have a 2007 Ford Expedition EL and at 37000 miles I have found that the paint is bubbling near the right side of the lic. plate. Ford has rejected the claim numerous times.

    Let me know if anybody has experienced this issue.
  • Very common problem. It is an aluminum tailgate so it is oxidation as opposed to rust. Some people have luck getting it fixed at no cost, others are not so lucky.
  • jkl4jkl4 Posts: 1
    Have an appt with the dealer to address peeling paint or plastic coated metal panel on the two panels flanking the back lift gate glass on 2007 Nav-L. It is peeling from the top down, no apparent rust.
  • I'd guess they will fix that for you. If it is the same as earlier models, it is an easy panel to switch, they are riveted into the body and with the quarter windows opened you have great access. I had one ripped off my car while it was in transit to me across the country and it was no big deal. It was a bigger deal that the thing held on for a while and gouged the quarter panel. Would have been nicer had it just come completely off.
  • One day after a hard rain my daughter says dad the car is leaking by the passenger door. Hmmmm, we thought it was the windshield, we climb up on the roof and every grooved slot is rotted out one cracked straight through.. Of course they deny the claim. Makes me sick.. 3K to replace te entire roof. I siliconed it up for now..">
Sign In or Register to comment.