Do Ford aluminum bodies corrode?
Design and protection: How Ford minimizes corrosion
Key protection features include:
- Aluminum panels with corrosion-resistant coatings and primer
- Protective sealants and sealed cavities to reduce moisture intrusion
- Adhesive bonding and dissimilar-metal isolation to minimize galvanic corrosion with the steel frame
- Underbody and wheel-well coatings to reduce exposure to salt and road grime
- Quality paint systems and prescribed maintenance to preserve coatings
These measures aim to reduce corrosion risk; however, damage to coatings or prolonged exposure to harsh environments can still lead to corrosion in vulnerable areas.
How corrosion can occur in Ford aluminum bodies
Even with protections, certain conditions can initiate corrosion. The main risks include:
- Damage to paint or clear coat exposing bare aluminum to moisture and salts
- Galvanic corrosion at joints where aluminum panels contact steel components if coatings are breached
- Moisture entrapment around trims, seals, and fastener sites
- Exposure to road salt, brackish water, or acidic environmental contaminants
- Aging coatings or repairs that introduce incompatible materials
In practice, corrosion that progresses to perforation is relatively uncommon when the vehicle is well-maintained and used in typical conditions.
Common areas to inspect
- Edges and seam lines where coatings may be thinner
- Door sills, rocker panels, and wheel-well rims where debris and moisture collect
- Joints where aluminum panels contact steel components
- Underbody coatings and protective films that may wear away
Regular inspection helps catch early corrosion so it can be treated before it worsens.
What owners can do to prevent corrosion
Practical steps owners can take to preserve aluminum body integrity include:
- Regularly wash the vehicle, including the underbody and wheel wells, to remove salt and grime
- Promptly repair paint chips and coating damage with approved primers and coatings
- Use protective waxes or coatings designed for aluminum panels
- Avoid abrasive cleaners or tools that can scratch the protective coatings
- Inspect seals and trim to prevent moisture entrapment; ensure drainage paths are clear
- Follow dealer recommendations for maintenance and service intervals
Taking these precautions reduces the chance of corrosion and helps maintain resale value and structural integrity.
Warranty and service considerations
Ford's corrosion-related coverage typically targets perforation of the sheet metal due to rust, and terms vary by market and model year. Always check your owner's manual or speak with a Ford dealer to confirm current warranty specifics for aluminum body panels and related components. Independent repairs using incompatible materials can impact corrosion protection.
In addition to warranty coverage, a good maintenance routine and addressing issues early are the best defense against corrosion on aluminum-bodied vehicles.
Summary
Ford’s aluminum-bodied vehicles are engineered to resist rust and corrosion, backed by protective coatings and thoughtful design that isolates aluminum from dissimilar metals. While corrosion is not common in normal use, it can occur if coatings are damaged or in harsh, salt-heavy environments. Regular cleaning, prompt paint repair, and adherence to warranty guidance help keep aluminum panels corrosion-free over the life of the vehicle.
