FREAKING OUT, Corrosion

[swampflyer]

I took a closer look at mine this morning. Just 1 hinge, right lower. I think I'll wait for the aftermarket to come out with a repair procedure. 2018 with 60k. Also out of warranty.

I've had my hood replaced by the dealer (great job) now I need to do the passenger side lower hinge like yours but my warranty has expired for 3 days and said they will try a good faith approval for repair. That means if approved I will have to pay part of the cost but don't know how much yet. I'm not complaining I have been with this dealer since 2006 and used them for several things and they treated me alright. I've purchased three jeeps through them and was satisfied with the process. If I don't get approval for the good faith repair then it's on me. I do recommend Daytona cdjr if you are looking, they treated me fair.

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[TheNewGuy]

The bolts used to mount them are steal, not aluminum like the doors themselves. So right there is two dissimilar metals in contact. Just going off boat math here, but using a anode (the shims) to eat the corrosion makes sense.

As you said, it's a prep issue which is the primary cause of the corrosion. Since the hinges are painted over it's very possible small bits from the threading, either on the bolt itself of the thread from the doors, is the original cause of the corrosion. Hell, it could be the drill that drilled the threads into the door living bits behind. It's possible the shims can counteract the corrosion process once it has begun, and allow them to eat most of the corrosion rather than the metal under the paint. The corrosion we see after all is just gas pockets forming under the paint from the chemical process. I'm not a material scientist so just spit balling here, but it makes sense to me

There are pics from a few different owners who preemptively removed their hinges to paint underneath that show the corrosion starting away from the center of the hinges where the bolts are. The bolts are not the issue. Raw aluminum under the hinges is.

 

[alphawolff]

There are pics from a few different owners who preemptively removed their hinges to paint underneath that show the corrosion starting away from the center of the hinges where the bolts are. The bolts are not the issue. Raw aluminum under the hinges is.

It's possible debris from the bolt installation due to improperly cleaned threads got under the hinges as well. The door and hinges are both aluminum, they shouldn't corrode without outside influence.

 

[alphawolff]

That makes perfect sense for the issues adjacent to the hinges.

There are also issues in areas nowhere near hinges. Yeah, we can try to further speculate on what could cause those, but even their engineers seem to be incapable of solving them all.

Same thing, debris during the paint process. The hinges are unique in that they're held together with a different type of metal (the bolt). Hood, door edges, etc, are just poor paint prep from the start.

 

[TheNewGuy]

It's possible debris from the bolt installation due to improperly cleaned threads got under the hinges as well. The door and hinges are both aluminum, they shouldn't corrode without outside influence.

Raw aluminum, if left outside, will 100% be effected by exposure to the elements

 

[Senior_Chief]

My 2020 JLU has all new hinges, doors, hood, swing gate, and windshield frame. Props to my dealer who got it all done under warrantee. I have been following this problem for two years. Not everything went all at once. Dealer stated that Stellantis footed the bill for north of $12K.

That being said, after all the research I have done, all there is, is speculation and contradiction as to the cause regardless of care and climate.

There are one or more "class action" suits filed but I got no response from the one I contacted.

The law suits seem like the only recourse if Stellantis won't step up.

Good luck!

 

[Chrisazm]

Really the problem is the metal plate behind the door frame that secures the bolts. That plus there isn’t a water tight seal at the hinge and door panel. One plus one equals

 

[Tim Scannell]

2018 JLU 4 Door Rubicon - I’m late to the game, my hinge areas are bubbling and chipping the paint (all 4 doors and the 2 hood hinges). I didn’t realize this was a widespread issue until a coworker told me their brother has the same issue and it was covered by warranty. I took it into the dealer immediately and they told me my corrosion warranty expired. They told me to call Jeep corporate, after 1.5 hours on the phone (mainly on hold) I have a case number but the jeep rep told me it likely wouldn’t go anywhere since the corrosion warranty was expired. Any advice? Or am I going to have to fork out my own money for new doors, paint job, and labor?

If the dealer you busted is the same where you purchased the car then go back and insist very loudly that you would like them to file a complaint with Chrysler , which approves the repairs. The problem is galvanic corrosion, reportedly caused by using zinc hinge pads on aluminum doors (there is a chemical reaction between the two metals.) the problem impacts Jeep Wranglers manufactured between 2018-2020 (I have a 2020 with paint bubbling on nearly every point on the car. I am on a very long list for repairs under warranty.).

Chrysler extended the normal 3 year warranty to five years, which means your time ran out in 2023. However, it is a manufacturing defect and several lawsuits have been filed. Your best bet is to file a complaint with the local AG and consider talking to a lawyer. Chrysler points to the problem in a service bulletin, although seems to be keeping the widespread issue quiet.

 

[Kitty31475]

2018 JLU 4 Door Rubicon - I’m late to the game, my hinge areas are bubbling and chipping the paint (all 4 doors and the 2 hood hinges). I didn’t realize this was a widespread issue until a coworker told me their brother has the same issue and it was covered by warranty. I took it into the dealer immediately and they told me my corrosion warranty expired. They told me to call Jeep corporate, after 1.5 hours on the phone (mainly on hold) I have a case number but the jeep rep told me it likely wouldn’t go anywhere since the corrosion warranty was expired. Any advice? Or am I going to have to fork out my own money for new doors, paint job, and labor?

I’m having same issues with my 2018 Sahara but mine didn’t start until warranty up. Have it same spots and just random on door. Got same reply from Jeep. Obviously it’s an ongoing issue, should be covered.

 

[Ratbert]

If the dealer you busted is the same where you purchased the car then go back and insist very loudly that you would like them to file a complaint with Chrysler , which approves the repairs. The problem is galvanic corrosion, reportedly caused by using zinc hinge pads on aluminum doors (there is a chemical reaction between the two metals.) the problem impacts Jeep Wranglers manufactured between 2018-2020 (I have a 2020 with paint bubbling on nearly every point on the car. I am on a very long list for repairs under warranty.).

Chrysler extended the normal 3 year warranty to five years, which means your time ran out in 2023. However, it is a manufacturing defect and several lawsuits have been filed. Your best bet is to file a complaint with the local AG and consider talking to a lawyer. Chrysler points to the problem in a service bulletin, although seems to be keeping the widespread issue quiet.

You're thinking it only impacts 2018-2020??? The TSB from 2023 covers through 2023:

 

[Tpack]

My JLU is in now for the corrosion remediation, 6 weeks for the repair. When I get it back it will have been at the dealer for a total of 3 months this year. Rear differential failure, CAN BUS failure(took multiple trips to fix), accident repair when the service department got in an accident test driving it (I chalk this up to S-Happens and just glad no one was hurt), and now 6 weeks to repair the hood, the doors and the tailgate. It's a 2020 JLU Sahara Altitude addition with 60K miles on it. It's a love hate relationship with the JL, but I think this will be my last new jeep. I have been a jeep owner since 1992 and owned 7 jeeps - two CJs, two YJs, a TJ, a JKU and the JLU. I'll probably end up with a used JK if I get another.

 

[tk1700]

This be at least 10-12K repair if you are out of pocket.

I noticed corrosion on 1 door hinge on my 2019 yesterday. I'm 93 days out of the 5yr corrosion warranty, and 78 of those days the Jeep was at the dealer getting the engine replaced.

I went to the dealer today and they said they weren't aware of corrosion or dissimilar metal issues. They said it was a paint defect and sent me to their body shop, which is at a Chevy dealer. Said the body shop would be able to see everything about the vehicle in their computer and could file a warranty claim to see what Jeep says. Body shop didn't have any answers. Again, no acknowledgement of any problems and it must be defective paint that was present when I bought the Jeep, brand new 5 years ago. They also said they couldn't file anything with Jeep and that they can't see my vehicle in their computer. Both dealerships are Larry H Miller.

The body shop gave me an estimate of $1060 to remove, disassemble, paint and reinstall 1 door. Thinking that was high I went to a body shop they quoted over $1600 for the same thing.

Currently working on an email for Jeep customer service to see what they will do. Yes, I'm past the warranty period by a few days. My take is this is that Jeep created this with poor engineering and assembly practices, they are aware of the problem as evidenced by 2 TSBs on the issue and they should extend the warranty period for corrosion created by their poor practices.

 

[MOTC JL]

I had the same problem three months ago with my 2018 JL. I took it to the dealer and they told me that I was good in that my Jeep was within the standard six year corrosion warranty. THey had it all fixed with no problem. Good figure........

Six year corrosion warranty? First time I heard of more than 5. What is the name of the dealer?

 

[ATBH9]

I had my Jeep evaluated at the dealership on Aug 2nd, 45 days before the corrosion warranty expired. I was told as long as the claim was submitted before the warranty expired the total expense would be covered. Sept 30 I was told that the parts were finally available, but now Stellantis had changed it's stance and since my warranty expired Sept 15 I would be required to cover 10% of the total cost, roughly $1400. Is anyone aware of this recent change to the claim process or experienced the same issue?

 

[MOTC JL]

Has anyone had the repair/paint job done successfully that can recommend a reputable shop in the greater SF Bay Area? The local dealer that I’ve been working with had a shop that did the repairs (before the updated TSB requiring replacement parts) but they no longer want to take it on. I would consider dropping it off at a body as far north as Santa Rosa or possibly down South towards San Jose. Thanks!

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