Hinge corrosion

jandersendo

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Maybe I’m going down a rabbit hole, maybe I’m not, but I just had a long discussion with one of my neighbors regarding the JK‘s and now the JL‘s hinge corrosion issues where the steel hinge reacts to the aluminum door and creates bubbling to the paint. I am sure since to 392 is not that old nobody has issues yet, but is anyone taking precautions against this? If so, what are you doing?
 
Maybe I’m going down a rabbit hole, maybe I’m not, but I just had a long discussion with one of my neighbors regarding the JK‘s and now the JL‘s hinge corrosion issues where the steel hinge reacts to the aluminum door and creates bubbling to the paint. I am sure since to 392 is not that old nobody has issues yet, but is anyone taking precautions against this? If so, what are you doing?
I don't know too much about the issue in question, except I've encountered galvanic corrosion issues in the past (on unrelated projects) and those issues are harsh. Off the top of my head, if anyone's making spacers out of buna or delrine, that would probably what I would try, but I don't know if the hardware is long enough to accommodate a spacer. Plus, the bolts could still interact with the aluminum I suppose.

Looking forward to hearing what someone with better understanding of the specific issue has to say.
 
I don't know too much about the issue in question, except I've encountered galvanic corrosion issues in the past (on unrelated projects) and those issues are harsh. Off the top of my head, if anyone's making spacers out of buna or delrine, that would probably what I would try, but I don't know if the hardware is long enough to accommodate a spacer. Plus, the bolts could still interact with the aluminum I suppose.

Looking forward to hearing what someone with better understanding of the specific issue has to say.
I was thinking PPF underneath the hinges may help?
 
I was thinking PPF underneath the hinges may help?
I mean, in theory, anything that prevents the contact between the dissimilar metals *should* make you safer... but then again those bolts through the aluminum would still worry me.

PPF would probably help, but I wouldn't count on it as a designed solution in case there are pinch points or any degradation over time.
 
I mean, in theory, anything that prevents the contact between the dissimilar metals *should* make you safer... but then again those bolts through the aluminum would still worry me.

PPF would probably help, but I wouldn't count on it as a designed solution in case there are pinch points or any degradation over time.
True. I’m asking some installers their thoughts. I’ll report back if I get any answers
 
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I mean, in theory, anything that prevents the contact between the dissimilar metals *should* make you safer... but then again those bolts through the aluminum would still worry me.

PPF would probably help, but I wouldn't count on it as a designed solution in case there are pinch points or any degradation over time.
A jeep shop just confirmed how common this issue is. Says some companies make billet aluminum hinges but that since the factory mopar ones are as well I don’t see how this helps. We need to get rid of the steel bolt…
 
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This problem was fixed on the JL. The door and hinge are made of the same metal.
 
This problem was fixed on the JL. The door and hinge are made of the same metal.
True they’re the same metal but the steel bolt going through them isn’t and no the problem is definitely not fixed:

https://www.jlwranglerforums.com/forum/threads/bubbles-in-paint-at-door-hinges.32756/

Some of these post scare me. An $80k jeep shouldn’t have these issues. I’ve decided to go with GenRight hinges which should help:

https://genright.com/products/black-anodized-aluminum-door-hinges-for-jeep-wrangler-jl.html
 
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True they’re the same metal but the steel bolt going through them isn’t and no the problem is definitely not fixed:

https://www.jlwranglerforums.com/forum/threads/bubbles-in-paint-at-door-hinges.32756/

Some of these post scare me. An $80k jeep shouldn’t have these issues. I’ve decided to go with GenRight hinges which should help:

https://genright.com/products/black-anodized-aluminum-door-hinges-for-jeep-wrangler-jl.html
Please let us know how those turn out...they look pretty nice. I have heard that when you remove the factory hinges, there's clear coat and such that shows the break in the paint...so if the new hinges don't line up perfectly (without re-painting everything), you might be able to tell. So let us know if you find an issue with that.

I've yet to receive my 392 yet, but my 2015 JK had the issue that I brought in & fixed just before the factory warranty ran out at 36K miles...it's been perfect ever since (5+ yrs).
 
Please let us know how those turn out...they look pretty nice. I have heard that when you remove the factory hinges, there's clear coat and such that shows the break in the paint...so if the new hinges don't line up perfectly (without re-painting everything), you might be able to tell. So let us know if you find an issue with that.

I've yet to receive my 392 yet, but my 2015 JK had the issue that I brought in & fixed just before the factory warranty ran out at 36K miles...it's been perfect ever since (5+ yrs).
Will do. When I get them I’ll make sure they’re bigger than than the factory ones to not have that issue. This whole thing worries me…. Shouldn’t have this on any vehicle let alone the 392.


Edit: by the look of the ones on their website your concerns shouldn’t be an issue. I hear GenRight stuff is too notch!
 

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Will do. When I get them I’ll make sure they’re bigger than than the factory ones to not have that issue. This whole thing worries me…. Shouldn’t have this on any vehicle let alone the 392.


Edit: by the look of the ones on their website your concerns shouldn’t be an issue. I hear GenRight stuff is too notch!
Agreed!! Jeep's had many years to figure this crap out.
 
I must be the only soul on the planet that doesn't have hinge rust and is not at all concerned about it.
 
I like to used BOESHIELD T9 Spray to get back behind the hinges. That stuff is very fluid and with capillary action will get in between panels effectively. I used T-9 inside a bunch of panels, not just the hinges. I’m also using STEK PPF but it is only over the outside of the hinges as a sacrificial film to protect against rock chips, branches, etc. PPF protects the paint, that in turn protects the metal below from corrosion. In the end the Jeep is just trying to return to its natural environmentally friendly state: iron oxide.
Aluminum oxide *
 
Really? 🫤

Look most of the Jeep is made out of steel. So if your parked it in the woods for 100 years, you would come back to a pile of rust (iron oxide) the natural state of all Jeeps for 81 years. The aluminum parts (doors) would probably still mostly be there protected by their aluminum oxide layer. Look at WW2 aircraft wrecks, a lot of them are still there after 81 years despite going down in some very harsh environments.

If your goal is to try and prevent the formation of aluminum oxide on your Jeep then I’m afraid you’re too late. An aluminum oxide layer forms in milliseconds after exposure. It actually slows down further oxidation of the aluminum. A little aluminum oxide is a good thing.
Steel on the other hand forms rust, which is air permeable and oxidation (rusting) continues to happen underneath. This is why surface rust eventually becomes a rusted through part over time. The key is time. This is also why the old “don’t worry about that spot, it’s just surface rust” is a very bad thing.

But to answer your original question which related more to galvanic corrosion (dissimilar metals) I suggested T9 as a barrier.

Doors and hinges are aluminum. Because of the untreated steel bolts through them, here’s a glimpse of our futures:
04191EA0-7555-4F66-A519-855E8FE654CC.png
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Has anyone removed the hinges and applied any materials between them to stop the galvanic corrosion?
im thinking of using a very thin layer of Teflon, bonded to high resistant film.
 
While it doesn't make the problem any less of a problem this has been going on for over a decade with Wranglers. Just like everyone else posting here I think it is ridiculous that Jeep hasn't changed the materials and build process to address the issue. The link below from 12 years ago sounds exactly like this one and a quick search will net you dozens of threads just like it.


I have ordered a 23 392 and I don't look forward to the day when I have to deal with corrosion but I'm not going to let it ruin enjoying my new Jeep. Turboencabulator's' posts above are a nice summation of the inevitable.
 
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