Interview Wanted - JL Rust Problems

[Dyolfknip74]

not Galvanic corrosion, which is what impacts most Jeeps.

Nope. It's aluminum on aluminum. It's corrosion from shitty paint prep. That's all. Also why it's at the bottom of doors and edges of hood. That's where water is settling in as it get under the paint.

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[Ratbert]

Wrong

And the bolts?

 

[Bill_B]

Bolts are steel but that is not what is causing the corrosion as you can see in areas where it goes down by the door and hood seams. To my knowledge the same material of fastener that ford has been using for many years on F series and all of their models with aluminum panels.


There is a very informative Facebook group of people haven’t already found it, lots of good info on there.

 

[Tim Scannell]

It’s not rust.

Definitely not a rust issue. It is galvanic corrosion, apparently caused through a chemical reaction between the paint and aluminum used in Wranglers since 2018 to lighten the vehicle and increase MPG. The issue is most predominant around hinges, but since it is a chemical reaction it does create paint bubbles around the door bottoms and even the hood.

I just brought my 2020 JL back to the dealer to document the issue to get within warranty parameters. The dealer knew of the problem and is in the process of contacting Chrysler to authorize repairs since it is a manufacturing defect. He admitted it would take a while to get repairs scheduled. He also noted there is no guarantee the new paint job will not eventually have the same problem. If that happens the car will be out of warranty and I will be out of luck.

The dealer, who was very responsive and helpful, also noted that proximity to salt water areas accelerates the problem. Again, it is not rust but a chemically produced corrosion. However, as the paint bubbles and flakes, rust may be an issue.

I do think more should be done by Chrysler, either compensation or in dire cases a buyback. I have noted on the forums that at least one lawyer is looking into a lemon law class action suit. The whole issue is unacceptable. My son has a 2011 Wrangler with no problems. People buy Jeeps fir the reputation for durability.

 

[Ratbert]

It is galvanic corrosion, apparently caused through a chemical reaction between the paint and aluminum used in Wranglers since 2018 to lighten the vehicle and increase MPG.

Galvanic corrosion is between dissimilar metals. Are you saying there's metal in some of our paint?

People buy Jeeps fir the reputation for durability.

Wait, we do?

 

[Tim Scannell]

In terms of the cause, no word from Chrysler as of yet except to say it is not rust but is galvanic corrosion. And yes, people buy jeeps for their durability, toughness, reputation, and cachet. Not sure if the enthusiasm lasts when things go bump in the night, though.

For example, when I reported my auto start/stop ceased working nine months ago I was told it was a battery problem. The best bet, I was advised, was to wait until both the primary and auxiliary battery need replacing to do the job - at a dealer cost of about $800! At that point, my cachet level dropped about 40 points!

 

[Ratbert]

In terms of the cause, no word from Chrysler as of yet except to say it is not rust but is galvanic corrosion.

It's obviously not rust. Aluminum doesn't rust. You said it was galvanic corrosion between the paint and aluminum, but galvanic corrosion requires two dissimilar metals, not aluminum and paint.

As others have noted (and corrected me on), the hinges are aluminum too. The bolts aren't, but the bubbling doesn't seem to typically be around the bolts. There are also many instances where the bubbling occurs nowhere near the hinges.

My best guess at this point would be old fashioned contamination resulting in a dissimilar metal getting on the aluminum.

 

[Dyolfknip74]

It's obviously not rust. Aluminum doesn't rust. You said it was galvanic corrosion between the paint and aluminum, but galvanic corrosion requires two dissimilar metals, not aluminum and paint.

As others have noted (and corrected me on), the hinges are aluminum too. The bolts aren't, but the bubbling doesn't seem to typically be around the bolts. There are also many instances where the bubbling occurs nowhere near the hinges.

My best guess at this point would be old fashioned contamination resulting in a dissimilar metal getting on the aluminum.

I dont even think it's that complicated. It's shitty paint prep and shitty paint. I think it's letting in small amounts of water and boom, bubbling. They paint over the hinge as well so every door slam is making microscopic patches of ingress to literal bare aluminum. Edges of doors and hood are lowest points to pool.

 

[Tim Scannell]

It's obviously not rust. Aluminum doesn't rust. You said it was galvanic corrosion between the paint and aluminum, but galvanic corrosion requires two dissimilar metals, not aluminum and paint.

As others have noted (and corrected me on), the hinges are aluminum too. The bolts aren't, but the bubbling doesn't seem to typically be around the bolts. There are also many instances where the bubbling occurs nowhere near the hinges.

My best guess at this point would be old fashioned contamination resulting in a dissimilar metal getting on the aluminum.

True, galvanic corrosion occurs between two chemically dissimilar metals and there may not be any metal in the paint (at least as far as we know.) But, it is basically an electrical reaction that occurs with one metal acting as the catgode and the other as the anode. The paint and any salted moisture in the air could very well act as an electrolyte and cause a reaction in the metal far from the hinges. I have bubbling on nearly every part of my 2020 JL. Bottom line is that it is a manufacturing defect and Chrysler is responsible for a permanent fix and associated costs to the owner (car rentals, transportation, lost work hours, etc.) In my case it is also a 130 mile round trip each time to my dealer.

 

[hamiamham69]

How is it that other car makers - I know, for example, on my 1997 Defender 90 - have figured out how to isolate dissimilar metals, correctly paint hinges and panels, and correctly choose the correct materials for fasteners. Its not that f-ing difficult.

 

[Ratbert]

A subsequent article about it: https://www.theautopian.com/stellantiss-aluminum-corrosion-issues-might-go-well-beyond-just-jeep/

Apparently Ford is the only manufacturer explicitly stating that it's galvanic corrosion and why:

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.

And companies like Ferrari have the same issue.

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