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Ford Expedition Rust and Paint Problems

We own a 2003 Expedition (bought new) with 28,000 miles. Noticed yesterday that there is rust under the bubbled paint surronding the rear door latch cover. We have meticously kept this vehicle clean and spray waxed. Has anyone else had this problem and have any solutions to offer? I purchased extended warranty when it was new.......any recourse?


  • tidestertidester Posts: 10,059
    You can get the feedback you want from owners in the main Ford Expedition discussion. Ford Expedition Owners: Problems & Solutions may also be helpful.

    tidester, host
  • tkhilliardtkhilliard Posts: 3
    i have the same problem. i got one small bubble on the outside of the hatch, and 5 bubbles inside the bottom of the hatch. ford dealership said it wont fix until theres an actual hole.or a tsb on it.(or tbs, something like that)
  • I've just discovered the same problem, bubbled paint on the rear hatch, near the latch and at the bottom edge of the door. My info says unless the rust causes a hole, the damage is only covered by the 3 year/36,000 warranty. Since I bought my Expedition in Oct 02 and it has 47,000 miles, I'm out of luck. Your original warranty could stilI be in force. Or if the extended warranty you bought is an extension of the bumper-to-bumper warranty you should be OK. I think it's crazy that a $40,000 vehicle, less than 4 years old is starting to rust, even if I do live in salt-crazy MN.
  • Hi tidester
    I took my 03 Expedition to the competing dealer in the city. My Expediton only has 23,000 miles on it. I had to pay $100.00 CDN and Ford did the rest as goodwill. Just out of curiosity is your Expediton lazer red? Mine is just wondering if the problem is with that color only. I also have extended warranty on mine ( I know it doesn't cover the paint but maybe it helped)
  • tidestertidester Posts: 10,059
    Hi, sixtiesrock!

    Actually, it was tkhilliard who said he has the problem with his Expedition. I was only directing him to where he might find additional help.

    tidester, host
  • froggie1froggie1 Posts: 1
    I have a 2003 Medium Wedgewood Blue Expedition and the same thing is happening to mine - in the same spot. I actually noticed the first small spot about about 3 months after I hit 36000 miles.
  • Hi froggie
    Must have been a bunch of them where they screwed up on the end gates. If you will notice the newer ones have a redesigned endgate. Best advice is go to your dealer and see if they will stand behind their product. Mention the goodwill thing from Ford. Good luck.
  • donsladonsla Posts: 1
    I had the same problem. The dealer fixed it under the 3/36 warranty. The running boards on one side also began to rust (sport ed). They replaced....I worry about this vehicle. Where can I get a good deal on a warranty?...I'd consider trading in but would "lose my shirt". So can anyone suggest a warranty plan??? Thx!
  • steverstever Posts: 52,683
    Check out the Extended Warranties discussion.

    Steve, Host
  • mentioned the goodwill thing, they laughed.
    so ended up buying primer paint and clear from work, so 130 bucks later i got my materials and gonna fix it myself. i paint for a living but just didnt think i should have to repaint and fix a 3 year old vehicle
  • steverstever Posts: 52,683
    mentioned the goodwill thing, they laughed.

    That's when you reply that you'll laugh all the way to the Chevy/Toyota/Nissan/Dodge dealer next time, but first you're going to tell all your friends at Edmunds about the rust.

    It might not hurt to keep your receipts in case people start getting them fixed by the factory.

    Steve, Host
  • explorerx4explorerx4 Central CTPosts: 12,039
    the thing is, it's up to you to earn the 'goodwill'.
    if you are not a regular service customer, forget it.
    the service department reviews your history and goes from there.
    i have gotten goodwill a couple of times on different vehicles. this is also known as 'awa'. it's good for 6 years or 75k, whichever comes first. you usually have to pay part of the repair too.
    2017 Ford Fusion SE 2014 Ford F-150 FX4
  • i've been searching around and there are ALOT of the new style (03 and up) with the rust spots on the hatch. youd think they'd do something. it would make them look better as a company to admit fault and repair,, to me anyway. when i was in there one tech mentioned something about the new style f-150 doors rusting on the bottoms and they are covered, but not the expedition hatch? kinda crappy but what can ya do.
  • fundadfundad Posts: 27
    Not true. Never had a vehicle in for service. I have always done my own. When the trany went on my explorer at 55,000 miles (19,000 miles past the warrantee) the dealer replaced it as good will and I only had to pay $38.00 for shop materials.
  • salty600xsalty600x Posts: 3
    I have a 03 gas guzzling expedition with the same rust bubble problem also, I thought it was just mine! BTW, just traded it in on a nissan murano that gets double the gas milage.. see ya
  • fundadfundad Posts: 27
    I went out today to wash my 03 E.B. and noticed the same. I checked it and found that the hatch is aluminum, not metal. Cant be rust I guess. lol
  • ekm1ekm1 Posts: 1
    I have a 03 Expedition under warranty for a few more weeks...blistering at the tailgate was fixed under warranty but now it is blistering on the inside panel with the outer skin meets the inner and blistering from the seam. They said they will fix it but will not cover it again if it blister more. Asked for replacement...said no, asked for additional 3 years on tailgate repairs...said no. Great company and products!!!
  • I just had the "bubbling paint" on the rear lift gate on my 03 Expedition fixed. They said the lift gate is aluminum so it isn't rust but bad paint/aluminum adhesion. My Expedition has nearly 50,000 miles, and I had no history with the dealership (the guy who sold me the truck had just changed dealerships 2 months prior), and they still fixed it under some vague "goodwill policy". They claimed that Ford would pay 60%, the dealership 20% and me 20%. I considered this an admission of guilt to a manufacturing defect and considered pushing for full payment by Ford/dealer. In the end I agreed to pay $200. I wonder how long this repair will last.
  • homey7homey7 Posts: 5
    I went to look at a 03 Expy for sale the other day and it had the same problem, it was red. Seems like wuite a large issue. I am now going to look at an 04. Maybe its a little better. Paint just does not stick to aluminum well. But it will at least reduce rust problems.
  • rowensrowens Posts: 1
    I have the same problem on my 2003 Grand Marquis except it is on the roof. The paint rises up and pops off. There is definitely rust underneath. Dealer told me that it had to rust a hole in the material before warranty would cover. Has anyone had this problem on other areas of their Ford or Mercury models?
  • 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.
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