Does Ford aluminum body rust?
Bottom line: aluminum body panels do not rust in the way traditional steel does, but they can experience corrosion under certain conditions. Ford began using aluminum for many body panels on its trucks, notably the F-150, starting in 2015, to reduce weight and improve efficiency. Here’s what that means for rust and corrosion on Ford aluminum bodies.
Aluminum vs rust: what actually happens
Rust is a form of iron oxide that develops when iron or steel is exposed to moisture and oxygen. Aluminum behaves differently: it naturally forms a protective oxide layer that helps prevent further corrosion. That protective layer can repair itself if damaged, but it isn’t invincible. In the right conditions—especially with exposure to salt, moisture, or dissimilar metals—the aluminum surface can corrode or pit, and nearby steel components can also be affected indirectly.
When corrosion can occur on aluminum bodies
The following scenarios describe common conditions that can lead to aluminum corrosion on vehicles. If you’re evaluating a Ford with an aluminum body, these are the situations to watch for.
- Damaged paint or clear coat that exposes bare aluminum, allowing moisture to interact with the metal.
- Prolonged exposure to road salt or coastal seawater, which lowers the protective barrier and accelerates chemical reactions.
- Galvanic corrosion where aluminum is in electrical contact with steel and an electrolyte (such as saltwater) is present.
- Crevice corrosion at joints, seams, or drainage channels where moisture can become trapped.
- Manufacturing defects or improper repair work that break the protective coatings or sealants.
In practice, Ford’s aluminum bodies are designed with protective coatings, sealants, and isolation strategies to minimize these risks. Regular maintenance and prompt attention to paint damage can significantly reduce the chance of corrosion taking hold.
Ford's approach and consumer risk
Ford shifted to aluminum exterior panels with the 2015 F-150, pairing them with a high-strength steel frame and specialized coatings to resist corrosion. The goal is to minimize rust in everyday driving, including in environments with road salt or humid conditions. While aluminum itself resists rust, corrosion can still occur if protective layers are breached or if aluminum is exposed to harsh conditions over time. Industry observers generally note that large-scale rust issues on Ford aluminum bodies have not been widely reported, but many experts emphasize that maintenance—such as keeping paint intact and washing off road salt—remains important for longevity.
Maintenance tips to protect aluminum bodies
To minimize corrosion risk on Ford aluminum bodies, consider these practical steps. The following list outlines actions you can take to help preserve the finish and protect against corrosion.
- Wash the undercarriage and wheel wells regularly, especially after winter or coastal exposure, to remove salt and moisture.
- Inspect for paint chips, scratches, or clear coat damage and have damaged areas repaired promptly.
- Avoid abrasive cleaners or harsh chemicals that can remove protective coatings.
- For joints and seams, ensure seals remain intact and address any water intrusion promptly.
- Have a professional inspect the body if you notice unusual discoloration, white deposits (aluminum oxide), or pitting in exposed areas.
Conclusion: while Ford’s aluminum bodies are designed to resist rust, vigilance matters. Proper maintenance and prompt repairs help keep aluminum panels corrosion-free longer, even in harsh climates.
Summary
Aluminum does not rust like steel, thanks to its protective oxide layer, and Ford’s aluminum bodies are engineered to resist corrosion. However, under conditions such as damaged paint, salt exposure, crevice formation, or galvanic contact with steel components, aluminum corrosion can occur. Regular cleaning, protective coatings, and timely repairs reduce risk, and overall, Ford’s aluminum-bodied vehicles have not shown widespread rust issues in typical ownership scenarios. Owners should monitor for paint damage and salt exposure, and consult a dealer or qualified shop if corrosion signs arise.
Does a Ford aluminum body corrode?
Durability and Corrosion Resistance: Aluminum does not rust like traditional steel, which gives the Ford F-250 aluminum body a considerable advantage in terms of longevity and maintenance costs.
Are Ford bodys aluminum?
Then, in 2017, they also started creating their F-Series Super-Duty trucks out of aluminum as well. This trend continues until today, with these two models using aluminum bodies, and all other Ford trucks having the typical steel bodies.
What are the benefits of the Ford aluminum body?
Aluminum: The Game Changer
Fuel efficiency: The aluminum body of the Ford F series reduces weight, which improves performance and increases fuel efficiency without sacrificing power. Corrosion resistance: Unlike Ford steel, aluminum doesn't rust, which extends the truck's life span and reduces maintenance costs.
Are Fords prone to rust?
Whether Fords rust easily depends on the specific model, year, and maintenance, but some models have had documented rust issues, particularly on underbody components. Modern Fords use aluminum for many body panels, which won't rust in the traditional sense but can corrode, while steel parts are still vulnerable to rust, especially in harsh climates. Regular washing, protection like undercoating, and cleaning out debris can help prevent rust on any vehicle.
Factors influencing Ford rust
- Older models: Some older Ford vehicles, particularly in the 1970s and 1980s, used less corrosion-resistant materials and had less robust rust-proofing, making them more susceptible to rust.
- Modern trucks: Recent models, especially Ford F-150s, have experienced reports of surface rust on underbody steel parts like the rear axle and differential housing, although Ford states this doesn't impact performance. This is because the body is aluminum, but many structural and drivetrain components are still steel.
- Climate and environment: Vehicles driven in areas with road salt, high humidity, or near coastal areas will rust more quickly than those in dry climates.
- Maintenance: Proper care is crucial for any vehicle. Areas that are difficult to clean, like the backsides of panels or under the truck, can trap moisture and road grime, accelerating rust.
How to prevent rust
- Wash regularly: Clean your vehicle, including the underbody, frequently, especially after driving on salty or muddy roads.
- Wax and seal: Applying a protective wax or sealant to the exterior can add a layer of protection.
- Undercoat: Consider an undercoating to add an extra protective layer to the vehicle's underside.
- Inspect and clean: Regularly inspect hard-to-reach areas for rust and clean out any accumulated dirt, salt, or debris.
- Protect against galvanic corrosion: With mixed-metal designs (like aluminum and steel), a process called galvanic corrosion can occur. Ford uses coatings to mitigate this, but it's something to be aware of.
