It didn't need to be done at a dealer with a body shop in my case. Local dealer farmed it out to a local shop.

 

Did they split the aluminum outer skin from the inner panel (fiberglass?), sandblast, prep, etc?

My local body shop does not have the equipment to split an aluminum skin and then re-attach.

 

They did not have to split it to address mine. The inner panel isnt fiberglass.

 

Hmmmmmm, 2 questions if you don't mind.

Was your corrosion only on the inside of the gate where the seam (folded lip) is or did it extend to both the bottom and around onto the exterior of the panel too?

If they did not split the panel, did they just grind down the bubbles, apply seam sealer and repaint?

 

the primary mess on mine was around liftgate handle. They did clean up the inside edge, but I assume it was a superficial sand and paint. They are going to see it again, it is now bubbling around the weatherstripping for the liftglass.

 

Thanks. That's why I am going to push for an entire new unit. If mine is this bad now, with pitting and everything, there is no way a simple grind and repaint is solving it.

 

well, I just picked the Expedition up from the Ford body shop. It's going back in next week. They were very upfront about the issue. Stated that there was a problem with paint adhesion and are going to redo the lift gate again. It worked out OK as they checked under the front hood and found a couple spots that need attention. They are going to fix them as well. At least they didn't try to pass it off. Kudo's to the body shop.

 

Good luck with that. I've never heard of that being done through all the years of this issue.

 

Let's just say you've heard it now.

 

I've heard of a plan for an attempt to try to get it done. Don't confuse effort with achievement.

 

My guess is that they were not aware of the TSB or did not follow it. Looking at the repair, it looks pretty good to me but they were not happy campers. I give them credit for not passing it off and sending me off on my merry way. They want it back and want to hit the underside hood as well. I think that's pretty upfront and fair. I'm not displeased.

 

No confusion here. It's already been approved by the mothership.

 

So two days ago you were thinking about pushing for a new tailgate, and now it has been approved? You must have pictures of goats at the district holiday party.

 

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

 

UPDATE:

So just wanted to update this tailgate issue. I wanted to wait until the process was completed before posting any further.

After seeing how quickly (3 months or so) the seam sealer caused corrosion went from a few small spots to the entire bottom lip and around to the exterior of the gate in a few spots, along with the inner hinge areas, it was time to get Ford to address it.

My local dealer after looking at it, advised me to find a Ford dealer with a body shop as they would have a better knowledge of the issue. Ford dealers with body shops are as rare as unicorns these days, but I happened to find one about 1.5 hours away. So totally unannounced, I showed up at their doorstep.

Body shop rep came out looked at the problem and said I will be right back. Couple minutes later, he comes back with his head tech. Body tech looks at it, and says it can not be repaired as it will keep coming back if done with the "grind and repaint" method Ford details in the TSB. He say's, "it needs to be replaced", to which I replied "exactly my thoughts" (I worked for quite some time as a body man, many years ago).

The rep took a bunch of pictures and sent them to Ford via their computer claims process. 10 minutes later, we had approval for the repair. This repair was to obtain new tailgate, prep, paint, R&R trim, etc. and so on.

In speaking about the repair, I explained that my biggest concern (and I mean a HUGE concern) was getting a paint match perfect as the repaint color (Bronze Fire Metallic) has to match the bumper, rear quarter wrap around and roof. If it doesn't match exactly, it is going to stand out like a sore thumb. The rep assured me it would be done correctly.

Ford had the gate on backorder, so that's why it took a couple months from the last post I made, but I picked up the truck yesterday and it looks fantastic. This Ford dealer uses the latest PPG system (water based) and using their new high tech camera system, and doing a spray out to ensure color match, they matched the color spot on.

This warranty work occurred within my vehicles bumper to bumper period, but even if yours is out of bumper to bumper warranty, the argument can certainly be made that it is a corrosion issue which has a much longer warranty, not a bumper to bumper issue.

As for the dealer who took care of me with nothing but smiles, updates and wanting to please the customer, it is Long-Lewis Ford in Muscle Shoals, AL and they have been around more more than 100 years. I did not buy my vehicle from them and have never had dealings with them prior to this but they will certainly be the first place I visit when it's time for my next Ford.