I'm looking at an 05 Navi, but noticed numerous places of corrosion (bubbled paint) on the underneath (bottom) of the hatch. I took it to a body shop, and they agreed it was corrosion. Also found out that hatch was aluminum, so not easily repairable.

Is this a common issue with 05 Navi's and Expeditons? Does anyone else have this issue?

I would think that Ford would warranty something like that.

 

It is a common problem, although it easily repairable. It is paint not ahhered to the aluminum. It has to do with bad surface prep at the factory. It needs to be stripped, prepped and reshot. Different people have had different success getting Ford to cover it. Some got it all, some got nothing. Probably not likely to get it as a second owner so figure it into your equation for purchasing it.