Paint Issues

[Darel]

Has anybody else had any paint issues with the paint bubbling, on inside of the door, on the lower hem flange? Just noticed this happening on our 2022 XLT. It's only happening on the right front door. We took it to our Ford dealer; they are trying to get Ford to replace the door. We're concerned that maybe the other doors might start doing it. I know Ford had this problem on some of the older Explorers. But I don't think this should be happening on a vehicle that isn't even 2 years old yet.

 

[peterk9]

Welcome to the Forum Darel.
Can you tell if the bubbling is due to rust? I don't recall any other posts with a similar issue. If they replace te door, I hope that they can get a good colour match. Please keep us updated. Thanks.

Peter

 

[Darel]

Welcome to the Forum Darel.
Can you tell if the bubbling is due to rust? I don't recall any other posts with a similar issue. If they replace te door, I hope that they can get a good colour match. Please keep us updated. Thanks.

Peter

It sure looks like rust. The bubbling is just above the seam sealer. I had a couple of local body shops look at it, none of them want to try and repair it. I too, am concerned about matching the paint, even though the vehicle is black. I know most people don't look at the inside bottom of their doors but was wondering if other members here could look and see if they had any issues with this.

 

[Darel]

Hmm--well 200 views & I guess nobody else has had this problem. Or maybe they're afraid to look, ldk. Anyway, hopefully the replacement door will not have this issue.

 

[RickyG]

Hmm--well 200 views & I guess nobody else has had this problem. Or maybe they're afraid to look, ldk. Anyway, hopefully the replacement door will not have this issue.

I haven’t heard of this issue from any other members

 

[Darel]

Well, Ford did replace the door. I was able to take it to a body shop of my choice. They did an excellent job on it. But I'm still not happy about having to replace the door on a fairly new vehicle.

 

[Crater]

Well, Ford did replace the door. I was able to take it to a body shop of my choice. They did an excellent job on it. But I'm still not happy about having to replace the door on a fairly new vehicle.

I have a '22 XLT with the exact same symptoms of creeping rust under the paint on the lower passenger door. I'll be taking it to the dealer to make it right. One of the rear passenger doors is slightly showing the same thing.

If Ford replaced the whole door, why did you need to take it to the body shop?

 

[peterk9]

...................................................

If Ford replaced the whole door, why did you need to take it to the body shop?

I'm guessing like some items, the doors do not come pre-painted. Also, I would think door replacements and the possible alignment would be a job for a body shop. I had a slightly misaligned driver's door on my 2017 Platinum and the service manager said if I wanted it fixed, They would send it to a body shop. Never did get that done.

Peter

 

[Darel]

I have a '22 XLT with the exact same symptoms of creeping rust under the paint on the lower passenger door. I'll be taking it to the dealer to make it right. One of the rear passenger doors is slightly showing the same thing.

If Ford replaced the whole door, why did you need to take it to the body shop?

Our Ford dealer did not have a body shop. We ask them if we could take it to a body shop of our choice. They said ok as long as Ford approved it. Ford paid for everything, including a rental vehicle.

 

[wwww]

I have the same problem on my 2020, passenger front is the worst and I've seen it on at least one other, though not as bad as mine. All doors appear to be starting underneath the seam sealer. Mine has now exceeded the 3 year ford corrosion warranty so it will be a fight it seems to try and get it covered. The seam sealer on the roof appears to be shrinking and has cracked the paint letting water under and starting to rust as well, right behind the windshield - especially the drivers side, I am thinking this is what is happening with the doors, some bad sealer that shrinks and splits the paint when it does.

It sure looks like rust. The bubbling is just above the seam sealer. I had a couple of local body shops look at it, none of them want to try and repair it. I too, am concerned about matching the paint, even though the vehicle is black. I know most people don't look at the inside bottom of their doors but was wondering if other members here could look and see if they had any issues with this.

 

[wwww]

I have the same problem on my 2020, passenger front is the worst and I've seen it on at least one other, though not as bad as mine. All doors appear to be starting underneath the seam sealer. Mine has now exceeded the 3 year ford corrosion warranty so it will be a fight it seems to try and get it covered. The seam sealer on the roof appears to be shrinking and has cracked the paint letting water under and starting to rust as well, right behind the windshield - especially the drivers side, I am thinking this is what is happening with the doors, some bad sealer that shrinks and splits the paint when it does.

P.s. I have been a red seal autobody technician for 20 years, I wouldn't think twice about replacing the door if you can get it covered, that is the only way to be rid of it. If you take it to any reputable shop they will not panel paint the door, the color will be blended out into the adjacent panels so that if there is a slight color variance it will not be noticeable.
If you see ANY amount of bubbling above or around the seam sealer it will almost certainly be much worse under that sealer. I would recommend stripping the sealer off and wire wheeling it and then trying to use a rust mort or similar rust converting chemical before using a 2k epoxy primer to protect before re-sealing (also with a 2k product that won't shrink) and then painting. And once you're all done painting, be it a new panel or a repaired one, make sure you fill it up with a good cavity wax from the inside.

 

[07EddyB]

Working on cleaning the interior of our 22 today so I was wiping down the door jambs. I had read this thread this morning but didn't think about it again until I got to the passenger from door. It literally looks like the bottom of the door is rusting out. All of the other doors are completely smooth.

 

[wwww]

Working on cleaning the interior of our 22 today so I was wiping down the door jambs. I had read this thread this morning but didn't think about it again until I got to the passenger from door. It literally looks like the bottom of the door is rusting out. All of the other doors are completely smooth.
View attachment 457874View attachment 457875

 

[wwww]

View attachment 457876

This is what it looks like under the sealer on the front right once you pick the sealer off, this was just a quick hit with the pressure washer while detailing. Have a look at the roof rail on the drivers side, peek under the roof moulding just behind the windshield and see if the sealer is split there as well, might just look like a hairline crack along the edge. This could let water in behind your windshield as well as rust out the windshield opening. my theory is that they used a poor quality sealer all over the vehicle that shrinks just enough to split the paint and let the water in.

 

[wwww]

This is what it looks like under the sealer on the front right once you pick the sealer off, this was just a quick hit with the pressure washer while detailing. Have a look at the roof rail on the drivers side, peek under the roof moulding just behind the windshield and see if the sealer is split there as well, might just look like a hairline crack along the edge. This could let water in behind your windshield as well as rust out the windshield opening. my theory is that they used a poor quality sealer all over the vehicle that shrinks just enough to split the paint and let the water in.

 

[07EddyB]

View attachment 457878

OK - you win. That's just lovely. We haven't hit our 3 year mark yet so we'll be taking it in. BTW - it gets parked in a garage every day. It doesn't even have 20K on it yet so it's been pampered. I don't even wash it very often and it's never been to a car wash.

 

[wwww]

OK - you win. That's just lovely. We haven't hit our 3 year mark yet so we'll be taking it in. BTW - it gets parked in a garage every day. It doesn't even have 20K on it yet so it's been pampered. I don't even wash it very often and it's never been to a car wash.

Mine is also parked under cover, didn't look too much worse than yours until the coating came off... I'm hoping they acknowledge this is a problem, it's on almost every one I've looked at now to some extent, on that same door. Mine is only at 75k km/45k miles and is in excellent condition otherwise

 

[wwww]

OK - you win. That's just lovely. We haven't hit our 3 year mark yet so we'll be taking it in. BTW - it gets parked in a garage every day. It doesn't even have 20K on it yet so it's been pampered. I don't even wash it very often and it's never been to a car wash.

P.s.... this is a competition I'd much rather not even be a part of much less be winning, lol

 

[peterk9]

^^ Welcome to the Forum.
That is unacceptable in my book. I'd be very interested in what the dealer/Ford has to say. Corrosion on aluminum panels is covered for 5 years, unlimited mileage but rust is another thing. Surface rust caused by exposure to the elements is not covered, The Corrosion Coverage Period covers sheet metal panels and is also for 5 years, unlimited mileage but only applies if the panel becomes perforated due to a manufacturing defect.
The picture seems to show surface rust that isn't perforated. Good luck.

Peter

 

[Darel]

Working on cleaning the interior of our 22 today so I was wiping down the door jambs. I had read this thread this morning but didn't think about it again until I got to the passenger from door. It literally looks like the bottom of the door is rusting out. All of the other doors are completely smooth.
View attachment 457874View attachment 457875

Yup, that's pretty much the way our passenger side front door looked. I did spray some fluid film in through the drain holes on the replacement door & the other doors. Hopefully this will help preventing this from happening again. Interesting that it seems it's the passenger side front door that is having this issue.