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Old 06-12-2014, 11:27 PM   #1
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Exclamation '93 YJ Rusted Frame. Help!

Evening all,

I have recently purchased my first jeep, a 1993 YJ 4.0L. When purchasing, I did not realize how bad the rust on the frame was. Where the rear leaf springs connect to the frame, it is completely corroded. The back right side is hardly in tact. I took a look at the rest of the frame today, and there are no holes, but there is very heavy rust along most of the frame. I need some tips on what I should do.

Should I continue to attempt to sand away the rust? If so, what is the BEST way to get thick rust off? Should I buy a shackle repair kit for $50 for the rear? If I were to strip down the jeep to the frame, can someone provide me with a link to a detailed guide on how to do this? I am a mechanic by the standards of the US Army; meaning I'm not an expert, but I can probably do it with a guide. Any help would be great.

Joshua

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Old 06-12-2014, 11:51 PM   #2
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I had a similar situation with my 91. It had major rust on the RR shackle mount and the entire front cross tube was nearly gone. I wound up finding sections of the same frame on eBay and used them to repair the one I had. If I had to do it again, I would buy an entire replacement frame. After I was done I saw a full frame with only surface rust for $500.

I used a couple of different wire wheels on an angle grinder to work the rust off the frame. Then a wipe down with a degreaser/wax remover and a coat of chassis saver gloss black paint. You can also use POR-15 and get similar results.

I decided to do a mostly frame off resto because I also had a lot of rot on the tub as well so I replaced it too. It's not my DD and I had the garage, time, and money to do it the way I wanted. Took me about 10 months with three months off during the winter. Right now I couldn't be happier with what I have accomplished. This was my first resto and I did everything but the front end alignment! Let me know if you decide to take on something like this.

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Old 06-13-2014, 01:40 AM   #3
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Old 06-13-2014, 04:11 AM   #4
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Have a pro welder evaluate over all frame condition,replacement frame pieces can be purchased from Quadratec....I replaced both sides of rear frame at shackle mounts on my 1990
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Old 06-13-2014, 12:03 PM   #5
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Thanks for the feedback everyone. I may strip the jeep to the frame and try to repair it with frame replacement parts. Tonight I'm going to take off the skid plate and see if rust goes all the way across the frame. I will take the wire wheel to it tonight. Anyone else have any great tips that I may need?
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Old 06-13-2014, 09:40 PM   #6
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Quote:
Originally Posted by ABT2RCK View Post
I had a similar situation with my 91. It had major rust on the RR shackle mount and the entire front cross tube was nearly gone. I wound up finding sections of the same frame on eBay and used them to repair the one I had. If I had to do it again, I would buy an entire replacement frame. After I was done I saw a full frame with only surface rust for $500.

I used a couple of different wire wheels on an angle grinder to work the rust off the frame. Then a wipe down with a degreaser/wax remover and a coat of chassis saver gloss black paint. You can also use POR-15 and get similar results.

I decided to do a mostly frame off resto because I also had a lot of rot on the tub as well so I replaced it too. It's not my DD and I had the garage, time, and money to do it the way I wanted. Took me about 10 months with three months off during the winter. Right now I couldn't be happier with what I have accomplished. This was my first resto and I did everything but the front end alignment! Let me know if you decide to take on something like this.

Tonight I was taking a wire wheel heavy to the frame from underneath the Jeep, and I actually was able to get a lot of stuff cleared up. I will get a degreaser, as well the chassis saver paint. There looks like a couple mounts that may need replacing, but I'll cross that bridge as I get closer to getting it on the road. I appreciate the tips.
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Old 06-13-2014, 09:55 PM   #7
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I went this route with rear shackle mount area ..... Auto Rust Technicians - since 1977

I did all the prep-work and just had a welder attach the new parts. Fit like a glove.


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Old 08-24-2014, 09:42 PM   #8
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did you have to drop the gas tank?
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Old 08-24-2014, 10:33 PM   #9
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did you have to drop the gas tank?
Yes, the gas tank has to be removed to make that repair. In his pic you can clearly see that the tank isn't in there.

The repair parts that he put on his, I have used on mine as well. And it is required to drop the tank, because the piece is made 3-sided and there is welding to be done on the inside of the frame rail.

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