As automotive journalists, we try to keep our finger on the pulse. What helps us even more is when our broad readership clues us in to what’s happening on the ground. Just this past week, I heard from John, who had read my piece on Jeep’s painful corrosion issues. He wrote in to let me know that the story goes deeper than just a single Stellantis brand.
John wrote in regarding his 2019 Chrysler Pacifica, which suffered a very similar issue to the Jeeps we’ve seen previously. “As you can see in the pictures, the paint on the hood was bubbling,” John told us. “I honestly don’t know when it started… maybe two years after I bought the car.”
What’s notable about John’s issue is that it comes down to one thing—aluminum. The Pacifica hood, like the Wrangler’s doors, is made of the lightweight material. Over the years, it’s been causing problems for Jeep, for Chrysler, and so many other brands—Stellantis and otherwise.
Flaky
The corrosion on John’s hood was quite unsightly. Bubbling occurred along much of the hood’s leading edge, with paint flaking off in places and leaving the metal exposed underneath. He also noted some paint flaking off the steel fenders, in the area hidden by the closed hood. Thankfully, he was able to get the ugly mess repaired, but not without some trouble.
“I was ultimately able to get the hood replaced under the factory corrosion warranty, but it was certainly a hassle,” he explains. He’d bought the car a ways away from his home in North Virginia, and that caused problems. “None of the dealers in the Northern Virginia area would touch the warranty work because I did not buy the car from them.”
Eventually, he was able to get the issue dealt with by the dealer that sold him the vehicle, over the border in Maryland. “The shop in Maryland, while inconvenient, did a nice job on the hood replacement,” he says. “The warranty wouldn’t touch the failed paint on the fenders.”
Was this just an oddball problem on John’s Pacifica? Well, he’s the investigative sort. He quickly found out that wasn’t the case. “I walked the parking lot during some downtime at my kid’s swim meet,” he explains. “I found six more Pacificas… five of them had the same corrosion on the aluminum hood.”
Anecdotal evidence from the dealership supported that theory. “The shop manager that I worked with said that this is a pretty common problem with Chryslers, apparently related to poor materials, cutting corners on prep, and working too fast,” says John. Plus, you can jump on just about any Chrysler forum, and you’ll find plenty of posts on the same topic.
Indeed, official documents stand testament to the widespread nature of the problem. Stellantis issued a Technical Service Bulletin in 2022 regarding “Aluminum Body Panel Corrosion Repair.” Under Vehicles Affected, you’ll find the Jeep Wrangler and Gladiator dating back to 2018, as well as the Chrysler Pacifica dating back to 2017.
Oh! But you’ll also find the Dodge Journey, Avenger, Dart, Challenger, Charger and Viper, dating back as early as 2013. Fiats, Alfa Romeos, and Ram pickups are implicated too. Basically, if it’s got an aluminum panel, Stellantis figured it could be affected.
The prime example seen on the TSB is the classic Jeep Wrangler hinge corrosion. The following example image shows it happening on the leading edge of a hood. Stellantis doesn’t outline a causative factor in the TSB. When we discussed the Jeep matter with the automaker, it put it down to “occasional variation in the manufacturing process.” The problem can be repaired in two ways. The panels can be sanded, treated with an anti-corrosion pen, and refinished. Alternatively, the panels can be replaced entirely if the aluminum corrosion has badly pitted the surface.
It’s worth noting that not all of these vehicles are built in the same factory. That would be a compelling common factor if it were the case, but it’s not. The Chrysler Pacifica is built in Windsor Assembly in Ontario, Canada. Meanwhile, the Jeep Wrangler and Gladiator are built at the Toledo Assembly Complex in Ohio. To say nothing of all the other Fiats, Dodges, and other cars called out on the same Technical Service Bulletin.
Not Just Stellantis
Fundamentally, it seems like Stellantis has had long-standing issues with reliably painting aluminum panels. But it’s not the only one. Ford has faced these same struggles.
In a technical service bulletin released in 2020, Ford tackled the problem of “Aluminum Panel Corrosion.” It covered all Ford, Lincoln, and Mercury products dating back to 2000, though only some had extensive use of aluminum body panels. “Some 2000 and newer Ford, Lincoln, and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust,” read the bulletin. “Panel replacement is recommended.”
In Ford’s case, we do have a rough idea of the cause. Going back all the way to 2004, an earlier TSB put the issue down to panels being contaminated with fine iron particles prior to painting. This caused galvanic corrosion thanks to the dissimilar metal reaction between the iron particles and the aluminum panel. This happened under the paint, causing bubbling and corrosion with ugly results. As read the bulletin:
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.
Ford had initially requested that repairs be undertaken by sanding and repainting the affected panels. The whole matter eventually ended up in a lawsuit, and Ford switched to recommending outright panel replacements instead.
Ferrari, too, has faced this issue. Rather infamously, the F12 is known for showing this characteristic bubbling under the paint, much to the frustration of owners. As seen in this video from AutoVlog, the problem looks remarkably similar to the flaking seen on Jeep and Chrysler product.
Curiouser And Curiouser
The big question remains—what’s going on here? Why are so many automakers having trouble with aluminum corrosion? And just as interestingly, why is it affecting some automakers more than others? Google will give you plenty of examples of Ferraris, Fords, Chryslers, and Jeeps with these issues. Meanwhile, Chevrolet has used aluminum panels for quite some time now, but examples of aluminum corrosion on its products are much harder to find.
Ford’s research does provide a compelling explanation for the problem, at least for its own vehicles. At the same time, it’s a little confusing that in so many vehicles, the problem first shows up on the edges of the hood. You would perhaps expect external iron contamination to land in nearly-random spots on a body panel, rather than always on the hood’s leading edge.
Went see an Ecoboost and noticed this bubbling on the hood. The hood was not properly aligned. 2015 Ecoboost that lived in Michigan. Should I be concerned? I would like to buy it, but what if they had an accident and the did a crappy job at fixing it? Carfax says there was a minor accident.
byu/huirosco inMustang
One problem we have is that automakers aren’t altogether forthcoming about why they’re having these problems. Barring Ford’s example above, none have really come out and said “our aluminum panels are corroding and seeing paint bubbling because of this single factor.”
This is something I intend to get to the bottom of in due time. Paint experts must be consulted, and more automakers asked for their explanation of the problems out in the wild.
Overall, though, it’s worth noting that there’s nothing fundamentally problematic with aluminum. Plenty of vehicles seem to use it without widespread problems. The hood on the original Mazda Miata is a great example, not exactly known for paint bubbling issues. So there must be a way to get it right—and a way to get it wrong.
Ultimately, one thing remains obvious. If you’ve got the bubbling on any car, panel replacement seems the most surefire repair. May the warranty be with you.
Image credits: Chrysler, John P (supplied), AutoVlog via YouTube screenshot
I have a 2021 Wrangler. It spent its first 3 years in Denver, garaged except for when at work. I moved to SC a year ago where it’s much more humid and it’s outside most of the time now so I’m paranoid about this starting to happen. There’s no signs of it yet, but really debating on whether I should keep this thing beyond the 5/60 corrosion warranty. I don’t want to have to pay for a respray OOP for this. It’s been problem-free otherwise but this makes me nervous.
Doesn’t Ford sell a massive amount of F-150s with aluminum bodies? Are they having problems?
It is pretty funny seeing the TSB with basically everything Stellantis has produced in the past decade on there. Way to go team!
2019 Pacifica – I just noticed about 3 weeks ago bubbling on the leading edge of my hood. I bought it about 3 years ago through Carvana. I can only imaging what kind of PITA it will be to get my local Stellantis dealer to repair it… (SIGH!)
Maybe that TSB will get it done more easily?
Do it fast…. your corrosion warranty is only good for 5 years.
Do Land Rover have any significant issues with this? They have been using aluminium panels for many decades.
I owned an all-aluminum xj8. In Michigan! Zero corrosion for 20 years. The owner and service manuals had lengthy warnings about never replacing a fastener except with a proper OEM replacement and using certain anti-galvanic pastes or insulating sealers. Likewise one was to exercise extreme care in maintaining the myriad of electrical grounds. Clearly they knew the potential for problems and how to avoid it. Similar experience with an Audi A8-no body corrosion for 20 years. Perhaps the 100% aluminum nature of these body shells is an advantage over the mixed nature of most of the cars we are discussing but it appears that the luxury makers understand alloy selection, engineering to avoid galvanic issues, and meticulous sterility in processing.
Usually the steel frame rusts away before the body is affected.
I was talking with the Old Man last weekend and mentioned this issue as he’s been thinking of buying a Gladiator. I was instantly informed about how all Toyota Tundra pickups need new engines 😛 MOPAR or no car!
This is a pretty well known issue among Pacifica owners. Hoods and the sliding doors, which are also aluminum. Pretty sure there’s a TSB specific to the Pacifica. On my list to call my local dealership and see if I can get some help with my door, even though it’s outside the corrosion warranty.
The tailgate is also aluminum. I’ve never noticed any issues on my doors or tailgate (thankfully). Good luck getting them to help out with yours!
I still think the Hero image should have been titled “Alumi-nom-nom-nom” with a photo of Cookie Monster at the wheel.
Please for the love of god fix the lead image. Aluminum cannot, does not, will not “rust”.
The issue at hand is corrosion which is most certainly different from rust.
It’s one thing if someone uses rust/corrosion interchangeably in a passing conversation, but when it’s the entire topic of the article, if you’re going to pretend to know enough about the topic to write an article throwing around phrases like “galvanic corrosion thanks to the dissimilar metal reaction between the iron particles and the aluminum panel” you should know the difference between rust and corrosion….
I had a 2018 Pacifica we bought new and had the same leading edge of the hood issue. It was minor, but it was covered under warranty. I did have to go to the dealer I bought it from rather than the dealer that had done all of the service. ”
The shop there was very familiar with the issues and said they’ve been doing a lot of them.
And I see no Comments about aluminum hoods or other body parts on Toyotas having such corrosion issues either. Process control issues, or rather the lack of sufficient feedback and change control.
It also seems to be FAR less of an issue for GM.
Even pretty new, I’ve got a 22 wrangler and it’s getting the bubbling along the front edge of the hood. It really doesn’t surprise me, despite David’s love of pretty much everything jeep, they have been made like s*** since at least when Chrysler bought the brand. I bought it knowing I would have to fix it, and it is really enjoyable to drive with the six speed and no roof or doors.
“None of the dealers in the Northern Virginia area would touch the warranty work because I did not buy the car from them.””
And I think that is complete bullshit and he should have complained to Chrysler about each one of those dealers not honouring the factory warranty.
Those dealers deserve to have the hammer come down on them.
But they are here to advocate for us consumers with the OEMs!! That is why dealers are so valuable!!
I did call Chrysler about it, actually. The nice lady I spoke with was sympathetic as a person, but from a corporate perspective, I was told to pound sand.
And that’s why Stellantis will continue to have terrible dealers.
My 2016 Grand Caravan was doing the same thing at the front lip of the hood at 4 years old and <80k miles.
Perhaps it really is caused by being made of melted beer cans.
Stellantis and Ford both make vehicles I would like to buy, but between this and the apparently widespread problems with some of their hybrid systems I’m really hesitant.
Exactly this. 2 long term automakers who in 2024 can’t get QC right? I’d love a Wrangler or Maverick…just not built by them.
-previous Ford owner who knew they couldn’t make good vehicles 30 years ago.
I’d have to go back and look, but I swear that I commented about this during on of the previous stories. Our 2017 Pacifica’s hood has been bubbling for some time. Maybe I wrote the comment but didn’t post it.
You may have! We try to read the majority of comments but we don’t get to all of them.
Thanks for tipping us off as well. We get great value out of what people write in to us.
“None of the dealers in the Northern Virginia area would touch the warranty work because I did not buy the car from them.”
I’m sorry…WHAT? Are we not even talking about dealerships not performing warranty work on cars they didn’t sell? I mean it’s not like he was trying to get them to repair a Lancia Ypsilon… It’s a freaking Pacifica.
Yep. Basically, Chrysler reimburses for warranty work in peanuts, and the dealers don’t want the liability of owning the warranty on the repair they perform. Which is not confidence-inspiring.
“Confidence-inspiring”? How about there’s-no-way-i’d-buy-a-chrysler-ing?
This basically precludes traveling to purchase a car
(based on price or availability, like XYZ dealer has that green you like)
Or, oh, say moving!!?
This is nuts
My Miata has had an aluminum hood for 20+ years and has no signs of this corrosion.
Have there been any changes to automotive paint that could be causing this? I assume a solvent or two has probably been banned or fallen out of favor in the last two decades.
It’s probably galvanic corrosion, so more likely prep than paint. Could be related to anodization chemicals, but I think those are usually acids that are relatively straightforward to deal with.
What I don’t get is that there is a decent amount of boat manufacturing in MI, and it’s relatively common to see engineers jump from automotive to marine employers and back.
Galvanic corrosion is a HUGE issue in boat building. It’s a consideration in literally every component that is installed. I’m not saying that everyone designing the body should have been aware of potential issues, but someone in the building should have been aware enough to mention it.
Galvanic was my thought too, or some reaction to the paint/primer
Worked for a motor company. Heard a tale of trying to diagnose massive motor failures at the factory. Turns out the steel wool was stored directly above the laminate stacks. Easy fix, but very difficult to find.
My technical background filled in a lot of blanks in that short story..
Also as someone who did a lot of troubleshooting and root cause analysis: HOLY CRAP!
That was a wild find..
They just kinda stumbled upon the fix too. Yeah, I need to do a better job of adding more color to my tales.
tldr; the steel wool was sprinkling steel wool dust down into the bare steel parts of an electric motor prior to assembly, leaving said debris to become part of the mechanical and electrical circuits
I have had a few really sticky issues where we started looking for nearby EMF or noise created by nearby machinery. However “look up” was never in my root cause toolbox. Wow.
We had stainless parts from a vendor arriving with rust. Turns out the vendor personnel did not understand the word “precede”. The instructions called for pickling preceded by cleaning. So, of course they dipped the parts in the pickling bath, and then into the contaminated cleaning bath. I never allowed the use of the word “precede” in technical documents I edited from then on.
Whoopsie-daisy! Words matter. Words matter so very a lot.
I’ve signed off on a few procedure documents in my time.
Regardless of the word “precede” and the tech’s vocabulary, I would never allow a procedure with things mentioned in the wrong order.
“Pickle…” Okay done. “… preceded by cleaning.” WTF?
Procedures should easy:
“Clean part.
Pickle part.”
like bad recipe in a cook book. “do this, but before you do that, do this other thing…”
Is there actual corrosion underneath the paint bubbling?
If there was, I would suspect a quality control issue with the aluminum composition.
If there wasn’t, it could be more a paint issue – lack of uniform cohesion to surface.
some weird galvanic issue, or catalyst in the paint/primer? I don’t think it would have to be compositional, although aluminum doesn’t usually corrode, it’s oxidation is generally self limited.
Depends on the composition of the aluminum alloy being used. I don’t know exactly what FCA/Stellantis/whatever they are calling themselves this week are using. But, inconsistencies in that manufacturing process could lead to unexpected corrosion.
Since most of the examples are either bubbling paint at edges, or bubbling paint at bends in the sheet metal, the prep theory would make sense if the issue was paint related only.
Corrosion is mentioned a few times here, but I don’t see any photos showing actual corrosion.
If you look at the TSBs from Stellantis, they show pitting corrosion under the paint
2017 Pacifica here with the same issue. Every time I take it into the dealer I mention it, they say they have to check with corporate and nothing happens. I don’t have the energy to bulldog it because there is a high likelihood I will end up trading it in eventually on another Pacifica then it will be their problem anyway.
Why would you go in for that again? Seems like the dealer sucks and is lying about trying to get it fixed for you. You like the Pacifica that much?
There’s a genuinely severe lack of competition in the minivan space right now.
Sorry, to be clear, I have never taken it in for just that issue, but mention it to them when I take it in for other work. The extent of the problem is relatively small compared to some of the pictures above so it really is a minor issue that doesn’t bother me much on our workhorse vehicle. I do really like the Pacifica. The problems that we have had with it have been pretty minor aside from things that aren’t the vehicle’s fault (gotta figure out how to keep rodents from eating the wiring harnesses) and it really works well for our family. As TT indicated below there aren’t many minivan options right now and the Pacifica is the best of that bunch for us.
Actually the rodent issue IS a fault of the vehicle. Makers are using wire insulation derived from things like soy. Rodents are attracted to it and devour it. Thank a combination of corporate greed and sacrificing the consumer to appease green activists
Honda has been selling 80-150k US-manufactured Pilots per year for 20 years with aluminum hoods and a wide range of colors, and the paint isn’t an issue for them. This is a Stellantis quality problem.
The hood on my 2019 RAM is doing this also unfortunately
My BMW G30 has aluminum hood, fenders, doors and trunk and I haven’t seen a single bubble. It’s funny that 25 years ago the E39 had aluminum suspension components (and many other cars followed suit) and you never see corrosion in those, even though they are exposed to the worst things a car will see (salt, moisture, dirt, grease, etc.)
PSA: Whenever you look at an uncoated aluminum or stainless steel part, your are looking at a fully “corroded” surface. It’s not that these materials don’t corrode, it’s that they generally form a nice thin and stable surface layer of corrosion which slows further corrosion down so much it effectively stops it (aluminum oxide on aluminum, and chromium oxide on stainless steels). This thin surface corrosion layer is also generally self-healing, in that if some of it gets scraped off it quickly reforms on the exposed surface. You only get what most of us recognize as corrosion on these types of materials when that ‘good’ corrosion layer gets disrupted and can’t reform properly.
Imagine a world where iron oxide formed a thin stable surface layer on steel parts instead of a flaky mess!
“Imagine a world where iron oxide formed a thin stable surface layer on steel parts instead of a flaky mess!”
Imagining…
https://m.youtube.com/watch?v=gb_0AvbeGQ8
Yup. I am aware of that and I’ve gotten into heated arguments explaining some people that yes, that whitish stuff that forms on top of aluminum is stable corrosion. But the article is clear that some manufacturers have an issue with cross-metal contamination, so even an already “corroded” suspension arm would start to pit and crumble if it had, say, iron particles embedded in it. I find it surprising that there are 25 year old cars on the road with aluminum suspension components that never had a single issue.
sold my 88 BMW 325 iX to a guy I know. one of the first to get the aluminum suspension components, no issue
Cor Ten
https://en.wikipedia.org/wiki/Weathering_steel
Range Rover Hoods have been aluminum for quite a while, I can’t say I ever noticed this on any of the ones we had on our lot.
When your reliability bar falls short of Range Rover, something’s gone pretty far wrong.