2022-2026 Stellantis Aluminum Panel Corrosion TSB

Symptoms of Aluminum Body Panel Corrosion

Owners of 2022-2026 Stellantis vehicles may observe "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." This issue is attributed to general corrosion conditions. This Stellantis aluminum corrosion repair bulletin provides guidance for addressing these symptoms.

Diagnosis and Trigger Conditions

Diagnosing aluminum body panel corrosion involves identifying the type and location of the imperfection. Technicians will refer to a detailed "Imperfection Decision Tree" (Fig. 1 in the TSB) to determine the appropriate course of action for this Stellantis aluminum corrosion repair.

The diagnosis process includes:

• Class A Surface Inspection: Checking for corrosion visible when the door or hood is closed (Fig. 2, 3, 4). If present, current warranty policy regarding digital imaging pre-authorization or Regional Office Approval must be consulted.
• Class B Surface Inspection: Checking for imperfections visible only when the door or hood is open. If found, Warranty Bulletin D-25-15 is used to decide on the necessary service action.
• Pitting Assessment: After removing blistered paint, if severe pitting remains that cannot be removed by sanding, panel replacement is required (Fig. 5).

Important Warnings for Owners and Technicians

• This Technical Service Bulletin (TSB) 31-001-25 specifically applies to aluminum panels. It is crucial to verify if a panel is aluminum by consulting the collision manual's material specifications.
• "Verify current warranty policy to determine if digital imaging pre-authorization is required or pre-approval is required from the Regional Office; depending on market." This step is critical before proceeding with any repair.
• "To avoid the risk of cross-contamination that will lead to galvanic corrosion issues, grinding/sanding and prep work must be done in a separate room away from ferrous material using only clean, non-contaminated abrasives." This prevents further damage.
• "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."
• "Avoid using tools or abrasive materials interchangeably with steel and aluminum components to avoid galvanic corrosion that may lead to a sub-standard finish."
• "For SA market only, after applying this TSB, it is not necessary to send DID-I or DID-A."

Repair Procedure Summary

The repair for aluminum body panel corrosion, as outlined in Stellantis TSB 31-001-25, involves a multi-step process to ensure proper adhesion and prevent future corrosion. The general procedure for this Stellantis aluminum corrosion repair is as follows:

1. Panel Removal: The affected aluminum panel is removed. Detailed service procedures are available in DealerCONNECT/Service Library.
2. Trim Removal: Any necessary trim components are removed to facilitate repair and refinishing.
3. Cleaning: The panel is thoroughly washed with soap and water, followed by wax and grease remover to eliminate contaminants.
4. Corrosion Removal: Corrosion is removed using an angle grinder with 80-grit or finer grinding discs. Roloc® 3" grinding discs or Clean 'N Strip discs may be used for difficult areas.
5. Sanding: Bare metal is sanded with 180-grit, and the old finish/repair area is feather-edged with 320-400 grit sandpaper.
6. Masking and Re-cleaning: The prepared area is masked for primer application and re-cleaned with wax and grease remover.
7. Primer Application: Clean, sanded bare aluminum areas are treated with a metal cleaner (e.g., Glasurit's 360-4) and prep wipes before applying two coats of an approved UV primer (e.g., BASF's Glasurit 151-170 UV Primer).
8. Curing and Block Sanding: The primer is cured using a UV lamp, then block-sanded with 500-grit or finer sandpaper.
9. Seam Sealer Application: If the backside of the panels required repair and seam sealer removal, it must be restored using approved sealers like Fusor 129 or 3M 08308. Seam sealer locations are identified in Service Library (Fig. 6).
10. Refinishing: The panel is prepared for refinishing, cleaned, and then sealer, basecoat, and clearcoat are applied according to the chosen paint manufacturer's procedures.
11. Reinstallation: The repaired panel and all removed trim components, including adhesive-backed items, are reinstalled.

Required Tools or Parts

Technicians will utilize specific materials for this Stellantis aluminum corrosion repair:

• Sandpaper: NPN 500-grit, 800-grit, and 180-grit sandpaper sheets.
• Discs: 3M® 3" Clean and Strip Disc (part number 07470 or equivalent).
• Scuffing Pad: 3M® Scotch-Brite Scuffing Pad Maroon (part number 07447*NPN or equivalent).
• Anti-Corrosion Pen: Part number 06103087AA.
• Approved UV Primers:
  • Akzo Nobel®: "Sikkens Autosurfacer UV"
  • Axalta®: "Cromax Premier LE3130S UV Primer Surfacer"
  • BASF®: "Glasurit 151-170 UV Primer filler, Grey"
  • PPG®: "SU1280 UV-Cured Primer Surfacer"
  • Sherwin Williams®: "UVP2 UV Primer"
• Seam Sealers: Fusor 129 or 3M 08308.
• Cleaners: Metal cleaner (e.g., Glasurit's 360-4), BASF 2000 Advanced Prep Wipes, Pre-Kleano 700 wax and grease remover.

Source: NHTSA ID: 11022003, TSB: 31-001-25