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Old 12-01-2010, 04:09 PM   #1
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Massive frame rust need help!!!! got pics

on my '99 tj i had new tires put in the other day and it felt like the tires were unbalanced and so my mechanic and he found a major issue with rust on the driver side frame rail. out of the three bolts holding the skid plate up two are rusted through. the entire lower part of the driverside frame needs to be replaced or fixed. i have a few pics of the damage. my mechanic told me to ask around to see if there was any kind of recall from the factory at any time for a '99 tj w/ 5 speed trans and 4 cylander engine. i need ideas on how to fix this or if its fixable at all.










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Old 12-01-2010, 04:12 PM   #2
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That sucks man...unfortunately I've never seen a recall for rust, it just happens to be where you hang your hat that causes that problem. The only way to repair that I would feel comfortable about is to plate it on 3 sides and weld the hell out of it.

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Old 12-01-2010, 04:21 PM   #3
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^^^ ditto.

Make sure you have a "experienced" welder do the work.
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Old 12-01-2010, 04:36 PM   #4
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well my mechanic told me a few years ago toyota had a recall due to parts of the frame that were alowing water to get into the frame causing them to rust away, he said at one time or another there may have been a recall to prevent this from happening.

he has a great welder working for him, he was thinking to take a squared off u bend 1/4" steel metal. he wants to cut out the bad stuff, perform some rust preventative stuff and weld the steel u bend in and than add one or two more bolts to each side on the skid.
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Old 12-01-2010, 05:06 PM   #5
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any other ideas on what to do
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Old 12-01-2010, 05:19 PM   #6
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My frame looked like that where it bends up to go over the rear axel. We cut out the worst of the rust and welded new steel over the holes.

I also had all 6 bolts that hold the transfer skid plate up rust to the point where they just spun in the holes and wouldn't come out. we cut holes in the side of the frame put in new grade 8 bolts with new nuts and welded the nuts in place. then put the piece of steel back and welded it back in place.
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Old 12-01-2010, 05:46 PM   #7
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yeah he was planning to cut holes in the new steel and welding bolts to the inside.
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Old 12-01-2010, 06:06 PM   #8
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That Toyota recall was mostly on the Tacoma IIRC. Something to do with the quality of metal used in the frame during a certain number of years of production. From what I've read in the past it was enough of a problem among Tacoma owners that dealerships were authorized to "buy back" the trucks and give the owners that amount towards a new Toyota.


Part of the problem here is how the skid meets up with the frame and traps moisture. Once fixed, you might consider putting a couple washers on each bolt to lower the skid a bit and let it breath.

That's a lot of rust. Obviously you're in danger of having the transmission fall out.

If you've got the funding and the time: Original Replacement Frame by Chrysler and Other Jeep Parts and Jeep Accessories by 4 Wheel Drive Hardware-RH2
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Old 12-01-2010, 06:18 PM   #9
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Yeah I can't afford that. After labor its gona cost more than what my Jeep is worth
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Old 12-01-2010, 06:26 PM   #10
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Might try and find a good condition frame at a salvage yard and cut those parts of it off if they will let you. Then do something like what the AEV Brute kits accomplish to stretch a TJ frame: sleeve inside the frame and then fishplate over top.
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Old 12-01-2010, 06:28 PM   #11
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Your mechanics plan sounds pretty good make sure the new steel overlaps the good old steel a decent amount. After its repaired pick up some POR15 chasis coat. It kills and prevents rust. Seeing your in CT sounds like it would be a great help to you. I'm doing it before winter myself to prevent my frame from rusting through.
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Old 12-01-2010, 06:52 PM   #12
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yeah he wants the u bend metal to go at least 3/4 of the way up or even higher.

and por15 is what will be used, i have a bunch of the marine clean, metal ready, and the por 15 left over from when i did the tub of my cj5
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Old 12-01-2010, 07:58 PM   #13
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that sucks, i saw this issue coming on my '97 two summers ago and did a por15 job on it... but when the winter time came around, i also took an air engine cleaner gun like this http://www.harborfreight.com/media/c...image_3727.jpg

Engine Cleaning Gun - Specialty Air Tools - Air Tools

take that hose and throw it in a container of used motor oil and spay the heck out of the undercarriage. inside and out of the frame in particular, kept the salt off the frame all winter! i'll be doing this again later in the week to my '04 and subie outback
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Old 12-02-2010, 05:38 AM   #14
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wow, I'm shocked. I'd expect something like this on a plow truck that sits all year ect...
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Old 12-03-2010, 04:05 PM   #15
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Problem i currently being fixed. and all for under $1000

his plan is to cut away all the bad rusted area, treat the inside of the frame as much as he can get to when he cuts away the rust, from there he is going to use 3 heavy gauge steel plating and weld it as high as he can(up to the body mount bracket)

he said he will have it done by thursday cause he is going to call in a more experienced welder than the one he has in the shop so that everything is done the correct way.
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Old 12-03-2010, 05:21 PM   #16
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why not buy a used frame from daveysjeep.com and throw it under your jeep and correct the problem?
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Old 12-03-2010, 05:35 PM   #17
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Money is the problem, he an easily get a new driverside frame rail and install it but i don't have the $2200 to have that done. when finished its gonna be just as strong or stronger than factory. and i asked him to take a few pics along the way, and he will be doing a little bit of work on the passenger side so that it doesn't happen to the passenger side frame rail. and for the price it a damn good deal, i'm lucky that the company i work for has 7 ford e-350's and a ford e-450 boxtruck and we have him service everything we own.
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Old 12-03-2010, 05:36 PM   #18
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the best part is that all of our vans have triton v-8's and the boxtruck is brand new with a triton v-10, im driving the newest e-350 for now.
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Old 12-07-2010, 06:54 PM   #19
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so far some of the work is complete on repairing the frame and have a few pics of what has been done, the only down side is i don't have the money to pay for it, so its gonna get done by the end of the week but he wants full payment before releasing it to me.




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Old 12-07-2010, 07:01 PM   #20
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Seems like fairly often people post wanting to know what to look for in a used Jeep. That's classic man. Sorry I don't have any answers.
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Old 12-07-2010, 07:53 PM   #21
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it didn't look too bad at first but after they did a little poking around and removing the loose stuff you can really see how bad it can get.
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Old 12-07-2010, 11:14 PM   #22
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you need a new frame.

in fact, i'll bet a frame swap will be cheaper than having a welder try to fix that.
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Old 12-08-2010, 05:53 AM   #23
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you need a new frame.

in fact, i'll bet a frame swap will be cheaper than having a welder try to fix that.
A frame swap is really involved and expensive,if the rusted out areas are just under were the trans skid was,a weld repair would be far cheaper....
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Old 12-08-2010, 06:24 AM   #24
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Were you under my Jeep taking my pics!?!?!?!?!?

I had 1 bolt holding up the right side, could put my finger through the holes in the frame. I've had 3 and have never seen a vehicle that rusts out as bad as Jeeps. The tranny skid plate is murder to find. I got a OEM from a Dealer in Ohio for $500 +$70 s/h. You won't find Wranglers in junk yards (Cherokees are a dime-a-dozen). Forget a frame swap, you could buy a newer Jeep and save thousands. Oh, $600 in welding and fabrication. Have you checked the body - another $600 for holes in the body behind my side steps. If you really want to get depressed...look under the new Jeeps that are STILL ON THE DEALER LOT.
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Old 12-08-2010, 08:26 AM   #25
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you need a new frame.

in fact, i'll bet a frame swap will be cheaper than having a welder try to fix that.
a frame rail replacement will cost around $2500, and i don't have that kind of money. he is gonna use 1/4" steel plates and weld them in, he is bringing in a welder who does mostly frame repair and rebuilds. i talked to the welder when i took the new photos and he said that the way he is gonna go about it will be stronger than the factory frame rail.
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Old 12-08-2010, 10:45 AM   #26
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A frame swap is really involved and expensive,if the rusted out areas are just under were the trans skid was,a weld repair would be far cheaper....
its not THAT bad...and it is cheaper if you do the labor yourself.

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a frame rail replacement will cost around $2500, and i don't have that kind of money. he is gonna use 1/4" steel plates and weld them in, he is bringing in a welder who does mostly frame repair and rebuilds. i talked to the welder when i took the new photos and he said that the way he is gonna go about it will be stronger than the factory frame rail.
do the labor yourself and it won't cost $2500. Call Davey's Jeeps and check on a used frame + shipping. Then check local junkyards....

My fear there with your welding repair has multiple implications.
1. The rust is very bad. The next thing that will rust out is the control arm mounts, and you don't know where else the metal is thinned greatly. You've also lost most of the material on the side of the frame rails itself, where you'd weld repair to..and you don't know how thinned out that is.
2. How are you going to reattach the skid plate? Tack a nut inside? If you ever need to replace it, you're screwed. Go back to nutserts?
3. The welding heat necessary over that much area could warp the frame. A pro-welder will know this and can compensate, but its still a problem. And the heat can damage other things...like the brake lines/fluid, plastic clips, hoses, etc.
4. Super beefy strong isn't necessarily better. Just means something else breaks/bends/twists.

Do what you want, but I still say a frame swap is easier and better in the long run. Theres a few guys that did it on JeepForum...
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Old 12-08-2010, 02:53 PM   #27
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1. yes the rust is bad, all the control arm mounts and swaybar mounts are all going to be beefed up on both sides, so just about everything attached to the frame is going to be checked and fixed/re-welded/replaced. there is also a lot of rust that has yet to be removed. everything is going to get checked and re checked to be structurally sound.

2. not sure what he is gonna do to attach the skid, but im sure its gonna be bolted with nuts welded to the inside of the new rail.

3. the welder is the best welder in the area and he does frame repair more than other welding i have seen what he can do and it all looks great and had several people told us to call him when me and my mechanic were calling around for a welder qualified to do the job and do it right

4. As said everything is going to be gone over to make sure there will never be a problem with the integrity and strength of the frame and everything attached to it.


and there is no way i could afford to buy a section of a frame and pay for it to be installed.
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Old 12-08-2010, 06:29 PM   #28
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you could find a from for a few hundred bucks.. would be a HELL of a lot easier if you or and friends had any mechanical ability..

heck i think i found a rubi frame with the drivetrain still attached for 3500.. which could be a GREAT upgrade for you IF you had the money..

but even if you get a frame for 5-600$.. you could paint it or use por-15 on it.. then you wont have to worry about rust for some time.. the suspension part would only take 4-6 hours.. (i had my whole suspension off minus control arms when i swapped my axles in and had it all back together in about 5 by myself) then youd just have to get the drivetrain/body back on which ive never done..
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Old 12-08-2010, 07:28 PM   #29
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time and money, don't have the time or the money to go and do it that way.
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Old 03-02-2011, 02:44 PM   #30
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For future reference.

http://www.autorust.com/Jeep_20pg_12.11.10.pdf

Sorry to hear about the rust man. Dealing with the lower control arm mounts on mine now and will be replacing the frame rails this summer. Also have a 1999 4 cyl.

I'm trying to get chrysler to do a new frame under the 10 year / 100,000 mile rust warranty as it is obvious these frames start rotting the second they roll out of the factory. E-Mail them. Make some noise like I did. Maybe they'll do something about it.

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