Ford Service Bulletin Shows Paint Defect on Many 2000-05 Models Ford has issued a Technical Service Bulletin that shows a major paint defect in many large 2000-05 Ford, Lincoln and Mercury cars, trucks and SUVs that used aluminum body parts (hoods and fenders) to reduce vehicle weight. Affected models are the 2000-04 Crown Victoria, Taurus, Expedition, F-150, Ranger; Mercury Grand Marquis, Sable; Lincoln LS, Town Car Navigator and the 2000-05 Explorer, Mercury Mountaineer. According to the TSB, “Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel. . . . Ford’s Scientific Research Laboratory has performed a number of tests on vehicle body parts returned for corrosion related concerns. Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prior to it being painted.” CAS Executive Director Clarence Ditlow said:”This is a very expensive defect to remedy. The TSB requires “extreme care to be taken” including special tools and segregated work areas to remove the corrosion by blasting, repriming and repainting. This repair is so difficult that CAS recommends the best fix is to replace the corroded part with a primed steel part and paint it. Ford cannot guarantee this repair will eliminate all the iron corrosion or prevent other areas from bubbling or blistering in the future.”Consumers who have experienced this problem are encouraged to file a complaint via our website.