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Old 08-15-2012, 10:39 PM   #1
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I lost 11 pounds today...of rust!

So as I am going through my new (to me) 2002 Wrangler Sport, I removed the tranny pan today, and HOLY CRAP RUST! I removed 11 pounds of rust today.



The pan looked fine when I started, with just a little rust on the side of the frame.




5 bolts came out no problem, one turned with the nut. Two of the frame nuts came right out of the frame, as did quite a bit of the driver's side frame bottom.



Looks like I'm going to call the guys at Auto Rust Technicians after all.

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Old 08-15-2012, 10:44 PM   #2
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Sweet jesus thats a lot of rust

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Old 08-15-2012, 11:19 PM   #3
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Damn, I'm glad I live in TX.
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Old 08-16-2012, 08:06 AM   #4
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Damn, I'm glad I live in TX.
X2 1998 and no rust at all.
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Old 08-16-2012, 08:13 AM   #5
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89 wrangler yj and i thought mine was bad, i have rust about the size of my palm on the rear part of my frame
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Old 08-16-2012, 08:33 AM   #6
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Honestly dude, it doesn't look like there's enough good steel on that rail to provide any foundation for a fix. I'd start looking for a frame. Once you have that new frame, keep it clean and washed out. Touch up any bare metal or rust and drop that skid at least a few times a year.
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Old 08-16-2012, 08:33 AM   #7
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OOOOHH Shit that's not good not good at all!!! Where do u live so I know not to leave my jeep there to long man mine is a 04 and not a spot of rust I go to the beach all the time in Tx and still no rust damn.... Looks like you will be on the hunt for a new fram or just cut it out and do the AEV Brute build and make it a Jeep truck....
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Old 08-16-2012, 08:49 AM   #8
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I had a similar issue although not quite as bad. Its a wonder the skid doesn't fall out
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Old 08-16-2012, 09:10 AM   #9
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That last picture looks like the Titanic..sorry man, that is some heavy rust damage..
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Old 08-16-2012, 10:12 AM   #10
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Right now, I am staying foolishly optimistic. I will start cutting back to clean metal this weekend. From the looks of it, the top and most of the sides look and feel great, paint is still holding on. It really is just the bottom rusting out.

The tub and engine look great, so does the exterior. I still think I can save her.

-Jim
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Old 08-16-2012, 10:24 AM   #11
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Good luck get a plasma cutter and go to town on it but I think ur better of getting a new fram or doing the AEV Brute build it probably will save u money and time if you just do it now instead of tring to fix that ungodly mess...
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Old 08-16-2012, 10:34 AM   #12
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Chrysler products are a POS!
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Old 08-16-2012, 11:07 AM   #13
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I also need to drop the skid plate, and this is exactly why I haven't yet. I'm betting my frame will end up looking a lot like yours.

I looked into what Autorust has, and they do sell a piece that covers that part of the frame with the nuts for the skid plate already welded on. Seems like as long as the top of the frame is solid there is something to weld the cap to.
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Old 08-16-2012, 11:43 AM   #14
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Any vehicle subject to snow and salt will end up looking the same way. I grew up in the detroit area and most cars had rust starting after 1-2 winters of driving.
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Old 08-16-2012, 12:02 PM   #15
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Any vehicle subject to snow and salt will end up looking the same way. I grew up in the detroit area and most cars had rust starting after 1-2 winters of driving.
That is the truth too it sucks!!!!
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Old 08-16-2012, 12:12 PM   #16
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I have a 97 with 163,000. I am in Pennsylvania, and mine us nowhere near that bad. I did a T-case drop 3 years ago, 5 out of 6 bolts cam out no problem one snapped off.
I wonder if using a washer between skid and frame would create enough of a gap so the water doesn't lay between them would help keep it from rotting out ?
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Old 08-16-2012, 12:32 PM   #17
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I have a 97 with 163,000. I am in Pennsylvania, and mine us nowhere near that bad. I did a T-case drop 3 years ago, 5 out of 6 bolts cam out no problem one snapped off.
I wonder if using a washer between skid and frame would create enough of a gap so the water doesn't lay between them would help keep it from rotting out ?

I have the same idea...my Jeep is rust free and always washed in the winter, but after seeing these pictures I think I am going to drop the skid a tiny amount (washers) to let air between the two pieces of metal...this should help prevent this problem.
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Old 08-16-2012, 01:17 PM   #18
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I have a 97 with 163,000. I am in Pennsylvania, and mine us nowhere near that bad. I did a T-case drop 3 years ago, 5 out of 6 bolts cam out no problem one snapped off.
I wonder if using a washer between skid and frame would create enough of a gap so the water doesn't lay between them would help keep it from rotting out ?
When I dropped the skid on my '99 here in RI I had some sheets of rust come off but not through the frame. I ground it, primed it with rust reformer and then sprayed again with undercoat. Then before sandwiching everything back together I spread a layer of marine grease to help stem the tide of rust. I'm dropping the skid soon to do another transmission oil change but I think the grease is holding up pretty well. I like your idea though. Definitely would let more salt wash onto the surfaces but it would dry easier.
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Old 08-16-2012, 03:16 PM   #19
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I have the same idea...my Jeep is rust free and always washed in the winter, but after seeing these pictures I think I am going to drop the skid a tiny amount (washers) to let air between the two pieces of metal...this should help prevent this problem.
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When I dropped the skid on my '99 here in RI I had some sheets of rust come off but not through the frame. I ground it, primed it with rust reformer and then sprayed again with undercoat. Then before sandwiching everything back together I spread a layer of marine grease to help stem the tide of rust. I'm dropping the skid soon to do another transmission oil change but I think the grease is holding up pretty well. I like your idea though. Definitely would let more salt wash onto the surfaces but it would dry easier.
Here is a kicker. I called my friend that sold me the Jeep, and told him what I found, and he said that he had the dealership replace the clutch less than a year ago, and do a 27 point inspection, and that they DIDN'T FIND ANYTHING!!!

Again my buddy, only drove this on the road, and never worked on it himself. But really, even a car novice should know enough to wash your car in the winter. I like the washer/spacer idea....when I get this all fixed!

-Jim
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Old 08-16-2012, 03:24 PM   #20
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This is exactly why I'm afraid to pull the skid plate on mine. I'm afraid mine is gonna look the same way.
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Old 08-16-2012, 03:57 PM   #21
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You can use the washer between the skid and frame, but it won't do you any good if it's rotting from inside the frame.
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Old 08-16-2012, 04:10 PM   #22
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Old 08-16-2012, 04:11 PM   #23
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You can use the washer between the skid and frame, but it won't do you any good if it's rotting from inside the frame.

Thats what internal frame coating is for. Although these frames like to rust from the inside if you look at peoples issues in this area it seems like it starts from moisture and salt etc trapped between two layers of metal...some space so it airs out and so I can shoot some wd40 on it from time to time would pay off Im sure.
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Old 08-16-2012, 04:20 PM   #24
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The solution to preventing such damage is very, very simple: Weekly washings & keeping the frames cleaned out.

Seriously, it's that easy.

Winter and salt aren't excuses.
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Old 08-16-2012, 06:44 PM   #25
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The solution to preventing such damage is very, very simple: Weekly washings & keeping the frames cleaned out.

Seriously, it's that easy.

Winter and salt aren't excuses.
That is true & I spray my undercarriage every time I go wheeling but Toyota trucks had frame rot prob & Toyota backed there product.I just think Chrysler should step up to the plate.
Here is my old frame.Did a frame swap and all good now.And yes,put in all new brake lines
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Old 08-16-2012, 06:47 PM   #26
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Right now, I am staying foolishly optimistic. I will start cutting back to clean metal this weekend. From the looks of it, the top and most of the sides look and feel great, paint is still holding on. It really is just the bottom rusting out.

The tub and engine look great, so does the exterior. I still think I can save her.

-Jim
Look over the rest of the frame closely before you start.I thought I only had a little bit of rot until I went to fix it.Then I found the holes in my last post.Just go over it CLOSELY!
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Old 08-16-2012, 08:10 PM   #27
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Holy Cow! If you fix this, maybe look at drilling/painting/rustproofing some drain holes and maybe covering the big open holes on the boxed frame sides in the wheel well areas? Looks like road salt/water splash has been pouring in and staying inside the enclosed frame.
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Old 08-17-2012, 07:06 PM   #28
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Are you going to try to fix this? I wouldn't drive it in that condition.
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Old 08-17-2012, 10:55 PM   #29
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Are you going to try to fix this? I wouldn't drive it in that condition.
I am going to fix it. Tonight, I took my grinder to the frame, and cut out about 18 inches or jagged rusty metal out of both sides of the frame. I am feeling better because I am finding out how much I have to repair. Knowledge is power. Long term plans are to find a clean frame and swap it out....that's next spring. Right now, I want to make it through this winter.

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Old 08-17-2012, 11:19 PM   #30
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