Caution! Frame rusted, unsafe

[ReefRaider]

The sections that tie to the cross members still looks fine so should be able to cut and repair without messing up the frame alignment. May have had a drain, but got plugged and rotted out. Nothing left there to know for sure. ****** deal, but not bad enough to warrant a new frame.

With out there being a factory repair procedure. No shop will accept the liability of that repair. Theres a lot of used frames out there. I should know have changed more than I can remember. Stopped fixing frames over 20 years ago. That is unless they will pay what it takes and most will not . Uts mostly about liability though.

 

[BWL]

How much labor is there in a frame swap plus frame? Has to be an 8k job minimum, but 10k+ would not surprise me. There's a reason insurance companies write off trucks vs replacing frames. Its a 14k truck max. I get the lifetime warranty thing, but they'll buy it out once repairs exceed value and a major component failure in the next few years would be the end of it. At least if the frame is repaired it wouldn't be a big personal loss if the engine blows 6 months later and you get a buyout less than the frame swap.if not for the warranty way better off just getting another truck if you feel frame swapis the only option. If you have transport in the meantime and you can diy the swap then it makes more sense.

 

[CYSTemrebel]

A lot of problems come from neglect and that applies to marriages, friendships, buildings and autos. My 300000 08 2500 after 11 years has only 1 problem and that is the rear wheel fender skirt area that rusts due to the pinch joint defect. That is the ONLY rust area on that truck. Bought a SET of repair units that replace that whole defective area and once they are traced and the existing rusty panels cut out, I can get at the problem that caused the rust. After that there will be no more problem, just like the front end aftermarket replacement with all joints greaseable by fittings.

Been watching the frame and note rust that my regular winter underbody flushing has not prevented. Attack plan will be a frame flush each fall and spring before and after winter salt season. I will use hydraulic oil which will not damage other material components. I am sure this will stop the surface rust dead and prevent deep frame rust causing frame pitting and destruction. All that entails is 16 hours a year. I presuppose this technique efficacy on the old timers whose trucks have lasted well over 20 years and who sprayed them with oil twice a year.

More proof? Sitting in my yard is a 1979 Chev van. I came into possession from my father who deceased 7 years ago when it went to one of my younger brothers. He let it sit in a gravel driveway for that 7 years starting it occasionally and gave it to me last fall. My mechanic neighbor with a shop put it on the hoist to inspect it and was shocked to see NO RUST of any consequence, body intact, and easily certifiable. It started easily with a new battery. It has 79000 MILES on it and my son insists on converting to 4WD. I have seen vans with these conversions. The auto 3 speed will be ditched and a standard installed, under direction of GM whiz who sold us the parts for the old army truck auto trans to standard conversion. He will sell us the necessary parts for the trans replacement and we will buy an after market 4WD conversion to be installed by my son with the help and direction of master mechanical GM neighbor. The secret of the intact body and frame on that 1979 Chev van 305 cu in? MY FATHER OILED IT TWICE A YEAR AS I WILL DO TO MY 08 DOGE 2500. That van has low mileage and 40 YEARS old. A stitch in time saves 9 applies to everything.

BTW, read that the Dodge 3500 is the most unreliable truck for 2019. hmmm

 

[GordDavey]

A Professional welder will weld the frame correctly. I just had the front section of my frame replaced. The welder does not do the entire weld in one shot. The do a little at a time and let it cool before doing more of the weld. That protects it without weakening the steel. The guy that did mine had been in the business 40+ yrs. He went back and forth to the different places, and welded a little bit at time, and when done it looked perfect.

 

[Forsakentalon]

A lot of problems come from neglect and that applies to marriages, friendships, buildings and autos. My 300000 08 2500 after 11 years has only 1 problem and that is the rear wheel fender skirt area that rusts due to the pinch joint defect. That is the ONLY rust area on that truck. Bought a SET of repair units that replace that whole defective area and once they are traced and the existing rusty panels cut out, I can get at the problem that caused the rust. After that there will be no more problem, just like the front end aftermarket replacement with all joints greaseable by fittings.

Been watching the frame and note rust that my regular winter underbody flushing has not prevented. Attack plan will be a frame flush each fall and spring before and after winter salt season. I will use hydraulic oil which will not damage other material components. I am sure this will stop the surface rust dead and prevent deep frame rust causing frame pitting and destruction. All that entails is 16 hours a year. I presuppose this technique efficacy on the old timers whose trucks have lasted well over 20 years and who sprayed them with oil twice a year.

More proof? Sitting in my yard is a 1979 Chev van. I came into possession from my father who deceased 7 years ago when it went to one of my younger brothers. He let it sit in a gravel driveway for that 7 years starting it occasionally and gave it to me last fall. My mechanic neighbor with a shop put it on the hoist to inspect it and was shocked to see NO RUST of any consequence, body intact, and easily certifiable. It started easily with a new battery. It has 79000 MILES on it and my son insists on converting to 4WD. I have seen vans with these conversions. The auto 3 speed will be ditched and a standard installed, under direction of GM whiz who sold us the parts for the old army truck auto trans to standard conversion. He will sell us the necessary parts for the trans replacement and we will buy an after market 4WD conversion to be installed by my son with the help and direction of master mechanical GM neighbor. The secret of the intact body and frame on that 1979 Chev van 305 cu in? MY FATHER OILED IT TWICE A YEAR AS I WILL DO TO MY 08 DOGE 2500. That van has low mileage and 40 YEARS old. A stitch in time saves 9 applies to everything.

BTW, read that the Dodge 3500 is the most unreliable truck for 2019. hmmm

Don't suppose I can harass you to explain how you do this using what type of fluid exactly? Thanks!

 

[chaz10]

Spoke to FCA they do not recommend welding frame. they are checking to see if a frame is avail. I have spoken to welders and frame shops they will not touch it.

 

[G-Ride990]

I don't understand why no one will touch it. What about guys that box and back half trucks? Many companies make and sell weld in c-notch kits, frame repair patches and all sorts of suspension setups that require frame welding.

Saying it won't be structurally sound, sounds a bit odd.

Have you contacted some off road fab shops yet?

 

[chrisbh17]

I don't understand why no one will touch it. What about guys that box and back half trucks? Many companies make and sell weld in c-notch kits, frame repair patches and all sorts of suspension setups that require frame welding.

Saying it won't be structurally sound, sounds a bit odd.

Have you contacted some off road fab shops yet?

This.

My dad bought a used 1972 Corvette back in 1985. There was a known issue with certain sections of the frame rusting through, GM had a factory approved welding fix. IIRC they even covered the repair back then, 13 years later. Had to go to an approved shop, but it got done and since it was factory approved, when we went to show the car and get it judged by NCRS, there were no points deductions because of it.

Granted, I figure todays frames are thinner and maybe not built as well, but surely *someone* could weld it correctly.

 

[Random_Walk]

That makes zero sense... I suspect "FCA" (I suspect the Service Advisor) is turning it down because of the time and expense (warranty be damned!)

 

[Krein]

Where at in PA are you?

If your close to the York area check these guys out.

https://steelfarmcustoms.com/

 

[dhay13]

My grandfather had a 1979 Chevy 1500 he bought new. Had an 8' bed and sold it years later to a guy that built street rods. He cut the frame and made it a shortbed truck. Truck was fine for years to come. FCA likely wants 1) you to buy a new truck rather than fix yours 2) wants to avoid the possibility of seeing their name in headlines after a bad frame caused a serious accident.
I agree that a competent fab shop can fix it and it will be just fine unless you are really stressing the truck to its limits

 

[ithaca4me]

I joined to say I have the exact same problem. I took mine in to the dealer to have the oil changed (I know but I have the million mile powertrain warranty and this way they cant say I am not taking care of it.) Any how they call me back and want to show me something and they showed me my frame is rusted so bad that when they tried to lift in one spot it crushed a little. My frame looks just like yours if not worse. I don't know how they didn't notice it when they done the fuel tank straps. It is worse on the drivers side just in front of the rear tire but the passenger side is not all that great. I took it to a frame shop and 1100 per side to fix. I filed a complaint with the NHTSA. The rest of the frame is fine and the truck looks great it has 131,000 on it.

 

[waynestractor]

It reminds me of the old Toyota 4x4's. They were boxed frames with a couple of tiny little drain holes that got plugged so the frames filled with dirt and crap and rusted out. I have removed and replaced the rot in many of them, and when it was done and repainted you could not tell they had been repaired. I had shops that were not interested in the jobs sending people to me due to the fact I had done so many and they looked factory when done. Finding shops that will weld frames is very difficult, as OP is finding out.

 

[ctdodge]

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??

 

[ithaca4me]

They issued a recall for the gas tank strap. HMMMMMMMMM but it is 10yrs old. Guess they probably don't do anything.

 

[RamminMopar]

But shouldn't a frame be able to more than 10 years? Unless marinated in salt water?

 

[16RamHemi]

imo pretty low expectations if you think a frame should only last 10 years. isnt the affected area on the bottom of the frame? how is treatment from below going to stop rot inside?

 

[chrisbh17]

But shouldn't a frame be able to more than 10 years? Unless marinated in salt water?

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

imo pretty low expectations if you think a frame should only last 10 years. isnt the affected area on the bottom of the frame? how is treatment from below going to stop rot inside?

You can shoot protection like Fluid Film, Corrosion Free, etc INSIDE the frame, there are plenty of openings to do so and get good coverage.

 

[JoeCo]

imo pretty low expectations if you think a frame should only last 10 years. isnt the affected area on the bottom of the frame? how is treatment from below going to stop rot inside?

Rust on the frame, sure, after one winter you'll have that. Large holes in the frame like that? Yeah that seems like a lot for 10 years in. Seen a lot of rusty frames in my lifetime in the northeast, ones that look like this are generally much much older.

 

[Casper]

Exactly, that’s almost laughable to say a weld will weaken it when the entire frame is welded together from the factory. Have a buddy who restores cars and replaces frame sections all the time and guess what they weld them together! Hell my 68 barracudas frame is spot welded in and made of sheet metal. I would say find a different frame shop and have that patched.

***
How often have you seen boxed frames on resto-mods to handle new power plants? When you box a frame you weld on strengthening material. No different that cutting out an area of cancer and replacing.