2013-2026 Stellantis Aluminum Body Panel Corrosion TSB

Stellantis has released Technical Service Bulletin (TSB) 31-001-25 REV. B, dated August 16, 2025, to provide guidance on diagnosing and repairing aluminum body panel corrosion. This bulletin supersedes the previous TSB 31-001-25 REV. A, issued on August 13, 2025, and includes updated information for technicians. The TSB applies to a broad range of 2013-2026 Stellantis vehicles across North America, South America, Middle East and Africa, India & Asia Pacific, Enlarged Europe, and China markets.

This TSB specifically focuses on "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." Owners of vehicles like the 2022 Alfa Romeo Stelvio experiencing this issue should be aware of the detailed repair process outlined in this document.

Symptoms of Aluminum Corrosion

Owners 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 visible deterioration indicates a corrosion condition on aluminum body panels.

Diagnosis of Aluminum Body Panel Corrosion

Diagnosing aluminum body panel corrosion involves assessing the severity and location of the imperfection. Technicians will first determine if the panel is aluminum by referring to the collision manual's material specifications. The TSB outlines a "Corrosion Imperfection Decision Tree" (Fig. 1) to guide the diagnosis process.

Corrosion is categorized into two classes:

• Class A: Visible without the door/hood/tailgate open. This includes corrosion on the leading edge (Fig. 3) or hinges (Fig. 4).
• Class B: Only visible with the door/hood/tailgate open.

For Class A corrosion, if pitting is found after sanding, replacement of the panel may be required. If the corrosion wraps into the hem, the panel should be replaced. For Class B, if there are holes or paint flaking, replacement is necessary. Otherwise, repair or touch-up may be sufficient. Warranty Bulletin D-25-15 is referenced for decision-making on service actions.

Important Warnings for Repair

Several critical warnings are highlighted in TSB 31-001-25 REV. B to ensure proper repair and prevent further damage:

• Cross-Contamination: "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 is crucial to prevent dissimilar metal reactions.
• Hinge 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."
• Corrosion Deterrent: "It is critical to apply the Bonderite 5700 Prep Wipes to deter corrosion." This step is essential for long-term corrosion prevention.

Repair Procedure Summary

The repair process for aluminum body panel corrosion is extensive and detailed, involving several steps to ensure a lasting fix. For the 2022 Alfa Romeo Stelvio and other affected models, the general procedure includes:

1. Panel Removal: The affected panel is removed. Detailed service procedures are available in DealerCONNECT/Service Library under Service Info > 23 - Body/Doors - Front/Panel, Door Trim/Removal.
2. Trim Removal: All necessary trim components are removed for access.
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 grinding discs. Roloc® 3” grinding discs and Clean 'N Strip discs may be used for hard-to-reach areas. It is vital to avoid using tools or abrasives interchangeably with steel and aluminum components to prevent galvanic corrosion.
5. Sanding: Bare metal is sanded with 180-grit. The old finish/repair area is feather-edged with 320-400-grit sandpaper.
6. Preparation for Primer: The prepared area is masked and re-cleaned.
7. Primer Application: Cleaned bare aluminum areas are treated with a metal cleaner, followed by Henkel - Bonderite 5700 Prep Wipes. Two coats of BASF's Glasurit 151-170 UV Primer are applied and cured using a UV lamp.
8. Refinishing Preparation: After curing, the area is block sanded with 500-grit sandpaper.
9. Seam Sealer (if applicable): If the backside of the panels required repair and seam sealer removal, it must be restored using Fusor 129 or 3M 08308 seam sealer.
10. Refinishing: The panel is prepared for refinishing by removing dust, cleaning with Pre-Kleano 700 wax and grease remover, and applying sealer, basecoat, and clearcoat according to the chosen paint manufacturer's procedures.
11. Installation: The repaired panel and removed trim components are reinstalled.

Required Tools and Parts

Technicians will require specific materials for this repair, including various sandpaper grits (180, 500, 800), 3M® 3" Clean and Strip Discs (p/n 07470 or equivalent), 3M® Scotch-Brite Scuffing Pads (p/n 07447*NPN or equivalent), and No - 5700 Henkel Metal Treatment (p/n 06103087AA). Approved UV primers from manufacturers like Akzo Nobel®, Axalta®, BASF®, PPG®, and Sherwin Williams® are also listed.

Paint Repair for Chips

For minor paint chips, a separate procedure is outlined:

1. Clean the chipped area with mild soap and water.
2. Re-clean using Wax and Grease Remover.
3. Use the Anti-Corrosion Pen (P/N 06103087AA) to treat the exposed metal.
4. Apply touch-up paint to the exposed bare metal and allow it to dry before returning the vehicle to service.

NHTSA ID: 11022011