We all need to watch for this in our new F150 in the next 1-2 years. I had no idea what it was until my 2011 Explorer which has an aluminum hood went for a detail today. I removed my front bug guard so they could wax behind it and was shocked what I found along the bottom hood edge, blistered bubbled paint at the hood edge in 4 spots. I thought the bug guard did it but after a quick trip to the body shop I was told it was known defect, galvanic corrosion. Checked the Explorer forum and low and behold this a big problem plaguing that model as well as older Mustangs. I have my fingers crossed that it doesn't show up on my new F150. Will have to fight Ford on the Explorer as it's out of the 3/36 warranty at this point. Google the topic if you want to get educated on this further.

 

It's been talked about. It's also why you must take your 2015+ F150 to a body shop that is Ford certified to repair the aluminum F150.

 

How was the bug guard attached ? With steel hardware? Are the 4 spots in the areas of the hardware?


Only reason I ask is, I worked for Ford from 08-14. Never saw galvanic corrosion on anything newer than 09. Doesn't mean that's how it happened, I've just never experienced a newer than 09 Ford with hood galvanic corrosion that just happened on its own. Seen it more times than I can count, with bug guards attached with steel hardware though

 

Steel hardware and the spots are not near the points. The guys on the Explorer forum didn't seem to have guards and had it happened and looked like what mine does at the rolled edge of hood. No bug guard on my F150 going the protective film route. Those considering bug guards may want to reconsider based on the interaction of steel hardware with the aluminum and net effect.

 

If you look closely at the points of interaction between steel and the aluminum of a new F150, you will notice a plastic gasket that isolates the two different metals. This gasket stops the electrollosis of dissimilar metals which causes white rust on the aluminum and can blister the paint.

 

Bingo... spot on !!

 

As long as the guard is properly mounted, there shouldn't be any chance for electrolysis. Sounds like the damaged vehicles had something wrong going on.

This isn't something new. Aluminum is used for many car hoods, not just the new F150. Aluminum isn't the problem here. The person(s) responsible for installing/choosing the bug guard is the problem.

 

Having spent better than part of thirty years in the aviation repair business, (one form or another,) working with aluminum structures is nothing new for me. Airplanes as most know are 90% or more aluminum. The issue of electrolysis is certainly nothing new and simply requires a different approach to metal working. All metals corrode. Left alone, steel much faster than aluminum. The two placed together, or for that matter any other "dissimilar metals" will do the same.


Whenever any metal object is drilled or exposed it will set off corrosion of the bare surface if proper steps are not taken to avoid it. Ford and all other manufacturers take steps to keep this from happening. Do it yourselfers and shops not knowledgeable in working with aluminum probably do not. Aircraft technicians are specifically trained at this. And as proven over the years, since before Lindbergh flew the Atlantic, corrosion can be controlled as proven by thousands of aircraft including air carriers flying machines well over thirty years old. And I might add in much harsher environments.


I would suggest that anybody who wishes to drill, grind or paint any aluminum object visit some of the online aircraft supply stores such as "Aircraft Spruce" and purchase the very inexpensive products to eliminate the issue mentioned above. It's a very simple process that will protect your investment.


Believe me, Ford is doing us all a great favor in taking this giant step. Aluminum is nothing to be afraid of. 747's landing at 200 MPH, weighing over 400,000 lbs landing weight is all that needs to be said for the strength and durability of aluminum. And each and every one does it well over 25000 times during the course of their service life without structural failures. Knocking 600 lbs off the weight of a truck simply has many more benefits than drawbacks. We just need to educate ourselves on how to work on the material.

 

Good post JetJoe. That's why I laugh when people are turned off by a *gasp* aluminum truck. "blah blah blah, I'd never buy a truck made out of beer cans, a real truck is steel blah blah". Sort of like those that bash the EB (nothing wrong with the 5.0 either, but stop with the "no truck should have a 6 cyl" argument). Times are changing and change can be good.

Aluminum, if handled properly, should be a fantastic material for this application. It is one of the reasons I decided not to even bother looking at the other manufacturers. Now, let's hope Ford got it right with respect to corrosion protection. One would assume that Ford consulted with folks from the aviation industry, where this expertise has been around for a long long time like Joe said.

 

So when doing speaker replacement we should look to use aluminum screws vs steel ones correct?