Caution! Frame rusted, unsafe

[chaz10]

I decided to order a new frame and change it with the help of my son in law, his dad owns a body shop, think we could do it in a weekend, Frame has been on back order for 3 months just got word it will not be available,
has any one converted to newer frame 2013-2019? I have found used in salvage yard but would like to use new.

 

[chaz10]

yes,I do think a frame should last more than 10 years, I have a friend uses 1978 Ford to plow snow, frame is still solid, and yes he does use it in the snow belt, he has replaced many body parts for rust, but the frame is still solid.
Dodge advertised the longest lasting line of trucks, sounds like that will be changing. all the literature when I purchased my truck called the frame "bulletproof"

I have restored a 59 chev original frame still good, I am restoring a 68 AMX frame/ unibody solid all are local vehicles

just frustrated new parts are not avail when they are still selling a truck that looks exactly like mine, and they know there was frame issues in that the were updated in 2013

 

[Quyonmob]

Frame swap in a weekend is an ambitious goal. Just disconnecting drivetrain and body is extremely time consuming, let alone moving it all onto a new frame and reconnecting.

I would be getting a fabricator to remove the rot, section in new steel, box it, and drive on.

 

[RamminMopar]

Actually if you leave it in the marinade it wouldnt rust, salt OR air does not equal rust. Salt AND air does.

Yeah true haha but like the guys near coastal waters that will dip their trucks in the salt water and then wonder why it's rusting.

 

[TomB 1269]

I agree with you frame should not rot out in 10 years. But from experience I can tell you that a replacement frame is not necessary talk to local racers, etc. and find the best damn welder in your area and most likely he will weld 3/8 to 1/4in patch panels to it. Now we all know that this only covers the rusted metal. However, a good welding shop will take the time to knock of the heavies rust, treat it with a rust converter, then weld in patches, and finally spray metal with a sealer/under coating. My 05 F150 FX4 had to have front passenger frame done, as well as both inside edges to rear frame just in front and in back of the rear leaf spring perch.

In addition, from the photos it looks as if your rust issues where the same as my Ford and all propagated along the factor weld seam. If this is the case and the metal is not compromised a full 360 in that area, then the frames integrity is still intact, but it's torsional rigidity is compromised until patches are installed.

I notice there is a lot of expectation that they will "cut and replace" in most cases like these that is not required and in most case not practical, and in some problematic. If you start cutting on the frame to remove all rust then you compromise the frame even further. In a frame off resto, that's fine as you have the body and weight off, in addition you can take measurements from every angle to assure its going back square. In this type of repair the idea is to slow and if possible stop the rust progression. Then to weld over a plate of steel that reaches far enough to be attached to good solid metal.

On my Ford, they had to do inner drivers frame beside gas tank. Taking the tank down just adds to problem and cost, so the weld a thicker plate up in beside the tank to span the problem area.

The steel they weld on will most likely out last the rest of the frame......

 

[TomB 1269]

Dumb question - why file a complaint with the NHTSA? The OP and ithaca4me are both 10 year old trucks that live in the rust belt. My guess is neither was ever treated to prevent rust - though that is ONLY a guess. What do you guys think the NHTSA is going to do - issue a recall? I could see filing a complaint if these trucks were a year or 2, but 10 years -- in the rust belt??

So cause I live in the north east I should expect my truck frame to rust out in 10 years..............???
A truck frame that has not been used for plowing and salting, and has not had major accident damage should remain intact for at least 20 years with basic maintenance. It is 1/4 in or thicker steel. However, thru the mid 2000 (i.e. Toyota Frame replacement period) the metals being used to make these frames, chevy, ford, dodge, etc. were flawed due to the tech they were using to build them, i.e. hydro forming. and they are all susceptible to this type of damage.

 

[TomB 1269]

I suspect Albany is a little to far for you, but George is the best around and tends to have a 30 to 45 day backlog. He did my Ford twice, and when I brought it in the 1st time he know what the issue was as well as checked other spot know to be of issue. He has done a lot of the 04 thru 08 Fords. Not sure about Dodges, but you're having the problem then he's probably seen it and fixed it.
https://www.facebook.com/GovelWeldingInc/

 

[Groo]

Frame rot is what kills vehicles these days it would seem. New frames are made to trap dirt inside of them, then you have that these hydroformed frames are drastically thinner than frame in the past, so it doesn't take too much corrosion to turn them into swiss cheese. I still have the first 2 new vehicles I have ever purchased. They are both off the road due to frame failures cause by rust. My 98 jeep Wrangler did get some frame patching, but that didn't stop it from ripping control links right off of the frame. I think I might do a frame swap on it as I can get an aftermarket replacement or build my own frame.
My 05 Avalanche, I knew the frame was going quickly because not too long before it failed, I put it on a jack stand to change the 4x4 solenoid, the frame started collapsing as I slowly eased it down. some moths later, the torsion bar cross member busted free from one side and it ripped out a brake line. I was hoping I still had a couple of years, but no. I am in the process of pulling the driveline and swapping it into a high mile 05 Yukon XL with a rod knock.
Both vehicles taken off the road with about 100k miles. and about 12 years on the road (pulled the Jeep off the road for a few years when I couldn't afford to repair it). I'll probably never do the Jeep based on how long it is taking me to do the GM without a hoist.

I would love to get a Power Wagon, but I can't afford to spend that much money on a truck that I can't be sure won't literally fall apart in 10-12 years. Ford's aluminum body trucks frames look the best for rust, so I might go that direction, but how can you be sure?

I am terrified of buying a used vehicle or a new vehicle these days. Do I fix up the old complete trashed 84 ram, only still on this earth because it was a year too old for cash for clunkers, that I learned to drive on? I have no clue what to do. Seriously, this is causing me a great deal of long term anxiety. I can't spend a few weeks wondering around Nevada to pick up a decent used truck that might last me long enough where the engine would fail before the frame.

 

[Ludville1]

After seeing this post I crawled under mine and looked at it. Both sides are solid with just a little surface rust. Then again, my truck was driven very little in the winter by the previous owner, and always cleaned well. It has not, and never will see snow or salt as long as I own it. We have an AWD Jeep Compass that gets winter duty.

 

[Tim7139]

Dumb question - why file a complaint with the NHTSA? The OP and ithaca4me are both 10 year old trucks that live in the rust belt. My guess is neither was ever treated to prevent rust - though that is ONLY a guess. What do you guys think the NHTSA is going to do - issue a recall? I could see filing a complaint if these trucks were a year or 2, but 10 years -- in the rust belt??

It's past the typical 10 year/120,000 mile design life, but it doesn't hurt. The NHTSA will let you know when you call if they will log it. They may have a case with lower mileage they're looking to flush out.

It reminds me of the old Toyota 4x4's.

That recall/lawsuit lead to coverage for 12 years or longer. The recall window for the Tacoma Leaf Springs a few years later was very short.

The Ford Windstar rust issues with subframes and rear axles were big news before, and then the Escapes again after. Seems like every year there are more reports of rust issues from different manufacturers. Mitsubishi had a cross members disconnecting from control arms this year.