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having recently aquired a '97, and after closly inspecting it I have found that the seam on the roof of the vehicle is spliting with rust. Im curiouse if anyone else has had this problem or even noticed.
I know three people with '97 Expys and ours that have no such problem. I did notice an Expedition in a Dealer body shop a while back that had been stolen and "lightly" rolled-over. The body shop had "peeled" the top panel off at each outer roof channel so they could replace it. Don't want to alarm you because it's probably not what happened to yours, but if you can do a history check for previous accident or body damage it might be worth while. It's just had to believe a modern car rusting like you describe.
I think they coat the seams with some kind of plastic that is subject to cracking. I have a '99 that has spent 90% of the time in the garage now shows signs of yellowing (its Ox White) and some small cracks. They probably haven't found a replacement for solder that lasts as long as the payments.
I had a problem like yours with my 1997 Explorer Sport before I sold it. I noticed rust spots appearing and the dealer was not sure why. He suggested that I have the roof acid washed (which one of their detailer's did) to have it removed and it worked. This stuff takes off the rust but not the paint which was good. Be careful with it though.
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