Aluminum Body Panel Corrosion Repair (31-002-22)

ALUMINUM BODY PANEL CORROSION REPAIR

TECHNICAL SERVICE BULLETIN

VEHICLES AFFECTED

2020 - **2024** (JT) Jeep Gladiator 

2019 - **2024** (BV) Jeep Renegade 

2015 - 2020 (4C) Alfa Romeo 4C 

2017 - 2020 (BA) FIAT 124 Spider (Convertible) 

2013 - 2019 (FF) FIAT 500 

2017 - **2024** (GA) Alfa Romeo Giulia 

2018 - **2025** (GU) Alfa Romeo Stelvio 

2014 - 2023 (KL) Jeep Cherokee 

2013 - **2018** (PF) Dodge Dart 

2013 - **2018** (ZD) Dodge Viper 

2013 - **2022** (DS) RAM 1500 Pickup 

2013 - 2022 (WK) Jeep Grand Cherokee 

2013 - **2022** (WD) Dodge Durango 

2017 - **2024** (RU) Chrysler Pacifica 

2015 - 2018 (BU) Jeep Renegade 

2018 - **2024** (JL) Jeep Wrangler 

2015 - **2021** (LA) Dodge Challenger 

2013 - 2014 (LC) Dodge Challenger 

2013 - 2023 (LX) Chrysler 300 

2017 - **2024** (MP) Jeep Compass 

2015 - 2017 (UF) Chrysler 200 

2019 - **2024** (D2, DD, DF, DJ and DP) RAM Heavy Duty Trucks 

CUSTOMER SYMPTOM

Aluminum corrosion or bubbling along the leading edge of hood, hinges or other exterior surface areas of the hinges, doors, fenders, swing gates or liftgates. 

CAUSE

**Corrosion conditions** 

REPAIR SUMMARY

This bulletin involves inspecting and if necessary removing corrosion and refinishing the suspect aluminum panels on the vehicle, hood, door, fenders, hinges, swing gates or liftgate panels.

SPARE PARTS

Qty	Part No.	Description	Notes
3 (AR)	NPN	500 grit Sandpaper Sheet
1 (AR)	NPN	800 grit Sandpaper Sheet
1 (AR)	NPN	80 grit Sandpaper Sheet
1 (AR)	NPN	180 grit Sandpaper Sheet
1 (AR)	NPN	3M® 3" Clean and Strip Disc 3M® p/n 07470 or equivalent
1(AR)	NPN	3M® Scotch-Brite Scuffing Disc 07467 Maroon or equivalent
1	06103087AA	Anti-Corrosion Pen

DISCUSSION

Aluminum corrosion or bubbling along the leading edge of hood, hinges or other exterior surface areas of the hinges, doors, fenders, swing gates or liftgates.

DIAGNOSIS

Aluminum corrosion or bubbling on the doors and/or hinges Fig. 2  .

Aluminum corrosion along the leading edge of hood or other exterior surface areas of the doors, fenders or liftgates Fig. 2  or Fig. 3  .

Is corrosion evident on the aluminum panel surface Fig. 2  or Fig. 3  ?

• YES>>> Consult current warranty policy to determine if digital imaging and/or Regional Office Approval is required before proceeding with repair, Proceed to Step 1  of the diagnosis procedure.
• NO>>> The repair does not apply.

1. Remove blistered paint from the panel surface with 80 grit grinding disc.
2. After digital imaging or Regional Office approval and removing the initial blistered paint from the panel surface with 80 grit grinding disc, is severe pitting exhibited that cannot be removed with sandpaper, 3M Clean and Strip Disc or equivalent Fig. 4  ?
   • YES>>> Replace the panel.
   • NO>>> Proceed to Step 1  of the repair procedure.

REPAIR PROCEDURE

1. Remove affected panel. Refer to the detailed service procedures available in DealerCONNECT/Service Library under: Service Info> 23 - Body/Doors - Front/Panel, Door Trim/Removal.
   CAUTION: Exterior mounted hinges should not be removed unless repair procedures, such as filiform corrosion repair underneath and around the hinge area, are required. Unnecessary removal of the hinges will risk further corrosion damage by breaking the paint around the perimeter of the hinge.
2. Remove all trim necessary for repairing and refinishing of the affected panel.
3. Wash the panel with soap and water to remove waterborne contaminants followed by wax and grease remover to remove solvent base contaminants.
4. Remove corrosion using an angle grinder equipped with grinding discs that are 80 grit or less. Do not use grinding discs courser that 80 grit.
   NOTE: Roloc® 3" grinding discs and/or Clean 'N Strip discs may be used for removing aluminum corrosion in difficult to access areas. Avoid using tools or abrasive materials interchangeably with steel and aluminum components to avoid galvanic corrosion that may lead to a sub-standard finish.
5. Sand bare metal with 180 grit.
6. Feather edge the old finish/repair area using 320-400 grit sandpaper.
7. Mask the prepared area for primer application.
8. Re-clean the repaired area with wax and grease remover.
   NOTE: BASF® will be referenced as the primary product. Other approved FCA refinish paint manufacturer brands are acceptable if equivalents are available. Refer to the list of FCA approved refinish paint manufacturers:

   Paint Supplier	Approved Paint Systems
   Akzo Nobel®	Lesonal, Sikkens
   Axalta®	Cromax, Spies Hecker, Standox
   BASF®	Glasurit, R-M
   PPG®	Deltron, Envirobase, Global, One Choice
   Sherwin Williams®	DeBeer, Martin Senour, Sherwin-Williams Automotive Finishes, Valspar

   NOTE: Refer to paint manufacturers' preparation and application recommendations.
   NOTE: Refer to paint manufacturers' mixing and application recommendations.
   NOTE: Refer to adhesive manufacturers' mixing and application recommendations.
9. Clean sanded bare aluminum areas using a metal cleaner such as Glasurit's 360-4 or equivalent followed by BASF 2000 Advanced Prep Wipes or equivalent prior to applying primer.
10. Apply two coats of BASF's Glasurit 151-170 UV Primer to the repair area.
11. Using a UV cure lamp and the appropriate PPE, cure the product for sanding and refinish preparation.
12. After curing, block sand with 500 grit or finer sandpaper to prepare the repair area for sealer application.
13. If the backside of the panels require repair and seam sealer removal was necessary, it must be restored. Apply Fusor 129 or 3M 08308 seam sealer or equivalent.
14. Prepare panel for refinishing, remove all remaining dust, clean with Pre-Kleano 700 wax and grease remover or equivalent and use a tack cloth to remove any remaining dust particles.
15. Apply sealer, basecoat and clearcoat per chosen paint manufacturer's procedures.
16. Install the repaired panel. Refer to the detailed service procedures available in DealerCONNECT/Service Library under: Service Info> 23 - Body/Doors - Front/Panel, Door Trim/Installation.
17. Install the removed trim components, including adhesive backed components (i.e. nameplates). **

POLICY

Information Only