[burnetma]

I am at that cross-roads where I have to make a big decision. My 1997 F250 is still running strong, but I am concerned about the body and chassis rust. I bought the truck new and it has spent it's entire life in upstate NY with tons of road salt. My primary concern is about chassis integrity and degradation of towing capacity. I intend to keep using the truck for conventional towing of loads upto 12,000 lbs. I do not see any holes in the frame yet, but maybe I haven't looked in the right places.

Questions:
1. How concerned should I be about the chassis rust?
2. How do I check and evaluate the rust?
3. Are there any known trouble spots to look?
4. Has anybody seen a frame or hitch failure?

I am in the position to upgrade to a newer truck and plan to look at used 2008's on Monday, but I am still not sure that I need to spend all of that money to remain safe.

 

[BlindViper]

I would check the areas around the leaf spring hangers. I personally have considered buying a frame from a truck down south. The economy sucks on the new trucks. You can't even work on the damn things anymore.

 

[roughneck97]

with all the problems that the new trucks have and you are guaranteed atleast a couple trips to the dealership for repair and the down time while its there. my suggestion is to look your truck over and compare the cost of any repair or repaires it may need to the cost of the new monthly payment and increase of insurance if any. you may be ahead to put a few bucks into what you have then buy a new one but its your call

 

[fordsforever73]

In my experience, I would take a weekend and pull the box off, pull spare tire off and have a good look. I used a chipping hammer where ever there was rust. It takes a while this way, but it works way better than a wire brush and less dust too. Good idea to wear a plastic face shield, safety glasses and a dust mask so you don't eat the stuff. With the box off is the best time to replace the rear spring hangers and shackles. as you can easily repace rivots with bolts/nuts. Have a look at fuel and brake lines while your there. If the bolts for the hitch look bad now's the time too. Have a good look at fuel tanks...usually dirt/rocks pile up on the skid plate and the tank rots out from rust or rocks rubbing through tank. If you feel real energetic, after cleaning rust, you can paint everywhere with a good quality rust paint and a brush. About rust...if I remember correctly my buddy, who is a welder, once told me that metal will swell/rust to ten times it's original thickness.

 

[S95]

have you been using any commercial anti-rust applications? RUST CHECK, KROWN , OR ???? i get mine sprayed every fall, i don't feel my truck is loosing any structural integrity. winter here goes from november to april and quite likely rivals your salt experience.

 

[burnetma]

Hey, thanks for all of the helpful advice. I will have to look into getting the truck checked over. Unfortunately, I do not have time to do it myself as my job is really demanding a lot of OT (unpaid). Paying somebody else may be cost prohibitive.

I already had to replace all of the brake lines, parking break cable (4 times) and both fuel tanks all due to rust. I am seeing rust under the cab and on the bed around the wheel wells. This is why I am concerned.

I know my front spring bushings are doing a bunch of shucking and I bet the rear hangers and bushings are doing the same.

I did a visual on the truck frame and hitch yesterday, crawling on my back. I did not find anything noteworthy, but then again, I need to look from the top down. Tomorrow's another day.

Thanks again.

 

[blageurt]

Put it up on a hoist and beat the frame with 30 ounce ball pein hammers. If it has a bell like ring the frame is ok . . . If it sounds hollow then it is going. You can repair the bad spots by "boxing" the frame . Or as was suggested previously go to Texas or anywhere they do not salt the roads and buy a truck without a powertrain Tow it back , and put yours in it .