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Under Hood Corrosion On 2007 and 2008 GT500s


War Eagle

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Guys have any of you been affected by this TSB yet? I have received emails from a couple of 2008 Mustang GT owners here in Florida that have the problem even though Ford stated that the problem was fixed after 2007.

thanks

Steve

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TSB 06-25-15 - ALUMINUM BODY PANELS - CORROSION - SERVICE TIP

Publication Date: December 11, 2006

 

FORD:

2000-2007 Crown Victoria, Taurus

2005-2006 Ford GT

2005-2007 Mustang

2000-2003 Ranger

2000-2007 Expedition

2002-2007 Explorer

2004-2007 F-150

2007 Explorer Sport Trac

LINCOLN:

2000-2006 Lincoln LS

2000-2007 Town Car, Navigator

MERCURY:

2000-2007 Grand Marquis, Sable

 

This article supersedes TSB 04-25-1 to update the vehicle model years.

ISSUE:

 

Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel.

ACTION:

 

This TSB provides service tips and procedures, outlining methods to properly prepare and protect aluminum body parts from cross contamination.

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, dolly's, 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.

 

NOTE: THIS PROCEDURE SHOULD ONLY BE USED ON NON-PERFORATED METAL. REVIEW WARRANTY AND POLICY MANUAL FOR VEHICLE WITH PERFORATED METAL.

 

NOTE: READ THIS PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE.

 

1. Corrosion should be removed by blasting. Use an aggressive blasting material, such as acrylic (salt grain size).

2. Use a DA sander with 180 grit paper backed abrasive. Only sand and featheredge the damaged area.

3. Mix and apply Ford approved epoxy primer, per the manufacturer's label instructions. Bake at 140° F (60° C), or use an infra-red lamp for curing.

4. If necessary, mix and apply two-part polyester filler to a slight over crown. Allow polyester filler to cure 20-30 minutes, or mix and apply spray polyester filler two-three (2-3) coats as necessary. Allow to cure per manufacturer's label instructions.

5. Hand-sand the repair area with 80 grit sand paper to remove excess filler.

6. Finish-sand the repair area with 400 grit sand paper.

7. Mix and apply Ford approved primer/surfacer per manufacturer's label instructions. Bake at 140° F (60° C) or use infra-red lamp for curing.

8. Sand the primer/surfacer with 400-600 grit to level the surface.

9. The next two steps are wet-on-wet. Mix and apply to hiding Ford recommended basecoat material per manufacturer's label instructions. Allow to flash.

10. Mix and apply two (2) coats (2 mils minimum) of Ford approved clearcoat per manufacturer's label instructions. Allow flash time. Finish bake at 140° F (60° C).

 

WARRANTY STATUS:

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THis would either happen on the hood but most likely the reason for the TSB is the aluminum coil covers. Several people have seen the blistering and I know someone that sent a set in a month or so ago for analysis at Ford.

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THis would either happen on the hood but most likely the reason for the TSB is the aluminum coil covers. Several people have seen the blistering and I know someone that sent a set in a month or so ago for analysis at Ford.

 

The reason I was asking is that I am doing some research on the problem and here is an example of an email I received. I also got one from a 2008 GT owner.

 

Steve

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"Quote

I understand your pain. My friend has a 06 GT with only 12k miles... Car is always under a cover, always detailed, always pampered.

 

The car is suffering from the body corosion that all new style mustangs 05-10 are suffering from. The metal under the paint is forming a white powdery residue from corrosion. The underside of the hood looks like an 89 as the paint is all bubbled up and crunchy from the corrosion. Ford said they will not repair the damage until it perforates the metal completely, so his babied car is going to eventually corrode to all hell. There is a TSB about the issue, but no real easy solution, as Ford does not want to replace panels or respray cars...

 

Sorry to hear your expensive stang is suffering from Ford's Job 1 crappy ass quality

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