Rust on four front body support brackets
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From: MA
Rust on four front body support brackets
I've noticed that the body support brackets on both sides of the radiator and the front cab support brackets on both sides are showing an awful amount of rust. Has anyone else had the same problem with their Expedition or F150? What is best way to repair or reinforce these brackets?
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From: Jersey Shore on the Right
Yes, I noted large chunks of rust falling off the front body mounts on my 99. I also noted one of the mounts had rusted totally through and you could see the crack flex if you pushed on the body. I found a cheap fix though - I got rid of it and bought a Sequoia. Buh Bye. 
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From: MA
I don't have any flex yet, but its only a matter of time. Before one of my brake lines ruptured about two months ago I was fat dumb and happy judging by the appearance of the exterior of my Exp and I thought this Exp would easily give me at least another 4-5 years of service, even here in the rust belt. Once I dug into the brake lines, transmission lines, transmission dipstick tube and driver side exhaust manifold, I have begun to realize that this EXP may be nearing the end. I am beginning to realize that Ford covers upthe potential rust ares very well with the plastic sheets held in with the plastic push fasteners. Unfortunately, I think the mistake I made on this vehicle is I trusted a mechanic who performed the repairs I requested very well but did not report any of the rust problems. Given that I am not in a position to buy a new vehicle because of my youngest child going to college, I need to figure out a way to make this vehicle last.
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From: Jersey Shore on the Right
Just to add more fuel to the fire - the rusted out body mounts was what pushed me over the edge. That was found shortly after spending a few hundred $ replacing the drivers side exhaust manifold and the assorted broken studs. Manifold noise was slightly improved so then it was easier to hear that there were issues on the other side. That's when I found 2 pin-holes in the passenger side manifold. That would never pass NJ inspection. Trans lines looked like they were ready to go and I was about 2 weeks away from a 2K mile round trip vacation to VT., NH, and ME. So with 98K total miles I traded it in.
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From: Trenton, MI
Well to tell you could add tar underbody it will slow down. Those are not expense to replace brake line, transmission line and transmission dipstick tube.
I know one guy who have 2003 Chevy 1500 HD replace brake line to rear axle because rust. In Michigan there are none Truck with no rust. Most is rusty due salt here.
You should check truck that been grow up in country on dirt road very rusty underbody.
Keep mind our 2001 F250 got bed rust in 2004 due we didn't wash during salt season.
I know one guy who have 2003 Chevy 1500 HD replace brake line to rear axle because rust. In Michigan there are none Truck with no rust. Most is rusty due salt here.
You should check truck that been grow up in country on dirt road very rusty underbody.
Keep mind our 2001 F250 got bed rust in 2004 due we didn't wash during salt season.
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From: MA
Just to add more fuel to the fire - the rusted out body mounts was what pushed me over the edge. That was found shortly after spending a few hundred $ replacing the drivers side exhaust manifold and the assorted broken studs. Manifold noise was slightly improved so then it was easier to hear that there were issues on the other side. That's when I found 2 pin-holes in the passenger side manifold. That would never pass NJ inspection. Trans lines looked like they were ready to go and I was about 2 weeks away from a 2K mile round trip vacation to VT., NH, and ME. So with 98K total miles I traded it in.
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From: Semper Fi tell I die!
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From: Fishkill, NY
I found the same rust on my 2000 expy. The front cab supports are ok and will be hit with rust converter and undercoated to heck asap. The ones on either side of the radiator are bad. I don't have any body flex, but there are some small holes through the supports. I might try something with angle iron to reinforce them, but that'll mean tearing everything ahead of the radiator off the truck. Everything's on hold until I can get things dried out... not likely until NY's monsoon season is over.
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Senior User
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From: MA
I found the same rust on my 2000 expy. The front cab supports are ok and will be hit with rust converter and undercoated to heck asap. The ones on either side of the radiator are bad. I don't have any body flex, but there are some small holes through the supports. I might try something with angle iron to reinforce them, but that'll mean tearing everything ahead of the radiator off the truck. Everything's on hold until I can get things dried out... not likely until NY's monsoon season is over.
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Joined: Nov 2004
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From: Fishkill, NY
I'll go get some lithium grease and slop it up. Just to protect it in the meantime. I found this mess while prepping my truck for a trip with the camper - so laying it up for an extensive bit of work isn't going to happen until the fall. I bought the Jayco trailer late last season and this is my first season with it. I figured... finally I have the right truck and the money to buy a camper... then I find this. I'm also not in a position to replace the Expedition with something comparable. Thanks for the suggestions, 98exp'.
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From: 0,0,1
Your one and only option is to bring the truck to a welding shop and have them fabricate a new mount.
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