Ford Super Duty Aluminum Body Problems

The new aluminum body on the Ford Super Duty trucks is having some serious problems. The trucks are rusting and the paint is peeling off. This is a big problem for Ford, because the Super Duty is their flagship truck.

They are supposed to be tough and durable, but this problem is making them look bad.

If you’re in the market for a new truck, you may want to think twice before opting for a Ford Super Duty. Reports have been coming in of serious problems with the aluminum body of these trucks, including corrosion and cracking. One owner reported that his truck began developing cracks in the body after just two years of ownership.

The problem has since gotten so bad that the entire bed of his truck is now held together with duct tape. Other owners have reported similar issues, with their trucks also showing signs of corrosion and structural damage after just a few years. Ford has acknowledged the problem and has issued a recall for affected vehicles.

However, many owners are understandably upset that their expensive trucks are already falling apart. It’s unclear at this time how widespread the problem is, but it’s definitely something to keep in mind if you’re shopping for a new Super Duty.

Ford Super Duty Aluminum Body Problems


Does Ford Have Aluminum Body Problems?

If you’re considering buying a Ford vehicle with an aluminum body, you may be wondering if there have been any reported problems with this type of construction. While it’s true that aluminum bodies are not without their challenges, Ford has worked hard to address the issues and ensure that their customers are satisfied. Here’s what you need to know about Ford’s aluminum body problems.

One of the most common concerns about aluminum bodied vehicles is that they are more susceptible to dents and dings than traditional steel bodied cars. This is because aluminum is a softer metal than steel, so it can be more easily damaged. However, Ford has taken steps to mitigate this problem by using high-strength aluminum alloy in key areas of the vehicle body such as the door pillars and roof cross members.

Additionally, all exterior panels are protected by a clearcoat paint finish which helps to resist damage from minor impacts. Another issue that has been raised about aluminum bodied cars is that they may be more prone to corrosion than steel cars. This is because Aluminum oxide forms a protective layer on the surface of the metal which prevents further corrosion.

However, this layer can be breached if the metal is scratched or damaged, exposing the bare metal underneath which can then corrode. To combat this issue, Ford applies a special primer to all exposed aluminum surfaces which helps to prevent corrosion. Additionally, all welds and seams are sealed using specialized tape which also inhibits corrosion.

Overall, while there have been some concerns raised aboutFord’s use of aluminum in their vehicles, they have taken steps to address these issues and provide their customers with quality products that will last for years to come.

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Do Ford Aluminum Bodies Rust?

If you’re worried about your Ford aluminum body rusting, don’t be. While aluminum does corrode, it’s much more resistant to rust than steel. So as long as you keep up with regular maintenance (like washing and waxing), your car should stay looking good for years to come.

But what if my Ford aluminum body does start to rust? If you do see some rust starting to form, don’t panic. There are a few things you can do to stop it in its tracks.

First, wash the area with soap and water to remove any dirt or debris that might be causing the problem. Then, use a metal polish or abrasive pad to buff out the corrosion. If the rust is still present after this, you may need to use a stronger cleaner like muriatic acid.

Just be sure to follow the instructions carefully and always wear gloves and eye protection when working with chemicals. Bottom line: Don’t worry about your Ford aluminum body rusting – it’s actually pretty resistant to corrosion. But if you do see some signs of rust, take action immediately by cleaning and polishing the affected area.

What Year Did Ford F250 Go to Aluminum Body?

The Ford F-250 first switched to an aluminum body in 1997. This was a major change for the truck, as previous models had always been made with steel bodies. The switch to aluminum helped to save weight and improve fuel economy.

It also made the truck more resistant to corrosion.

Can Ford Aluminum Body Be Repaired?

Yes, Ford aluminum body can be repaired. However, it is important to take note of a few things before attempting any repairs. First, aluminum is a much softer metal than steel, so any repair will require more care and attention to detail.

Second, because aluminum oxide is not as conductive as iron oxide, welding or brazing may be required instead of standard soldering techniques. Finally, always consult a professional body shop before attempting any repairs yourself.

[Explained] 3 Common Ford Super Duty Aluminum Body Problems

Ford F350 Aluminum Body Problems

The new Ford F350 has been generating a lot of buzz, and not all of it is good. Some owners are reporting serious problems with the truck’s aluminum body, including premature corrosion and paint defects. One owner reported that his truck began to show signs of corrosion after just six months of ownership.

The problem seems to be particularly prevalent in areas where salt is used on the roads, as it can speed up the oxidation process. Another owner had to have his entire truck repainted due to extensive paint defects. Ford is aware of the problem and has issued a service bulletin to dealerships outlining the issue and how to deal with it.

In some cases, repairs may be covered under warranty, but for many owners, they will be facing expensive out-of-pocket costs. It’s still early days for the new F350, so it remains to be seen how widespread these problems will become. In the meantime, if you’re considering buying one of these trucks, make sure you’re aware of the potential issues so you can make an informed decision.

Ford Aluminum Body Vs Road Salt

If you live in a snowy climate, then you know how important it is to have a car that can handle the elements. In this post, we’ll be comparing the Ford aluminum body to road salt to see which one is better equipped to deal with the winter weather. The first thing to consider is the material that each vehicle is made of.

The Ford aluminum body is much lighter than traditional steel bodies, which gives it some advantages when it comes to dealing with snow and ice. The lighter weight means that the car will be less likely to get bogged down in heavy snow, and it will also be easier to push around if you need to clear a path. Road salt, on the other hand, is very corrosive.

It can eat away at metal surfaces, causing them to rust and break down over time. This can be a major problem for cars that are made of steel, as the salt will eventually cause holes and weak spots in the metal. Aluminum, however, is much more resistant to corrosion from road salt.

So, which material is better suited for dealing with winter weather? Based on our comparison, it seems clear that aluminum has the upper hand when it comes to longevity and durability. Road salt may cause some cosmetic damage over time, but it won’t actually affect the structure of your car like it would if it were made of steel.

If you’re looking for a vehicle that can withstand everything that winter throws at it, then an aluminum-bodied Ford might just be what you’re looking for.

F-150 Aluminum Body Problems

When it comes to trucks, the Ford F-150 is one of the most popular models on the market. But in recent years, some owners have been having problems with the aluminum body of the truck. The main issue seems to be with the door handles.

In some cases, the handles have come completely off while people are driving. This can obviously be a very dangerous situation if it happens while you’re on the highway. There have also been reports of doors and tailgates that won’t open or close properly because of issues with the aluminum body.

This can make it very difficult to load or unload your truck. Ford has issued a recall for certain model years of the F-150 due to these problems, but some owners are still having issues even after getting their truck repaired. If you own an F-150, it’s important to keep an eye out for any potential problems with your truck’s body.

And if you do experience any issues, make sure to contact Ford so they can help resolve the problem.

2022 Ford Super Duty Problems

The all-new 2022 Ford Super Duty has been completely redesigned, and while it looks amazing, there are already some problems being reported. The most common problem is with the Power Stroke diesel engine, which is having issues with the fuel injectors. There have also been reports of the transmission slipping and hard shifting.

While these problems are certainly concerning, it’s important to remember that the all-new Super Duty has only been on sale for a few months and any new vehicle is going to have some teething issues. Hopefully Ford can get these problems sorted out quickly so that owners can enjoy their amazing new trucks!


The Ford Super Duty is a line of heavy-duty trucks that have been in production since 1998. In recent years, Ford has switched to using an aluminum body for these trucks. However, this change has caused some problems.

Some owners have reported that the aluminum body is more prone to denting and scratching than the previous steel bodies. Others have said that the new bodies are not as tough as they should be and that they flex too much. Ford has acknowledged these issues and is working on solutions.

In the meantime, some owners are choosing to switch back to the steel body or buy aftermarket products to protect their investment.


  • Zayn

    John Zayn Smith is a renowned truck enthusiast, automotive industry expert, and author. Beginning his career as a mechanic, Zayn's curiosity led him to explore all facets of the trucking world, sharing his insights through in-depth articles on His knowledge spans truck mechanics, trends, and aftermarket modifications, making him a trusted resource for both professionals and hobbyists. Outside writing and mechanics, Zayn enjoys off-roading, truck shows, and family time. Follow his work for the latest in truck-related news and tips.

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