Is my Explorer no longer safe to drive? *Rust*

[98FordLove]

Just going by the structural integrity. The rocker panel on the passenger side fell off a few weeks ago. Is this something that I should be replacing? Especially come winter time in Canada.

And then I looked at the side of the body and a lot of rust And some of it came off just from tapping it gently with my foot.

So that makes me think is this cars structure too compromised to be driven safely?

 

[Rick]

The body has definitely lost a lot of strength due to the rot. It won't be able to proect against impact nearly as well as it should. It's definitely repairable by welding in new steel. I would also check where the body mounts attach to the frame as that area is super important safety wise.

 

[C420sailor]

Frame still looks good.

Everyone has different tolerances when it comes to body rot. Frame rot is largely non-negotiable, so you’re looking good on that front.

 

[94Eddie]

Just going by the structural integrity. The rocker panel on the passenger side fell off a few weeks ago. Is this something that I should be replacing? Especially come winter time in Canada.

And then I looked at the side of the body and a lot of rust And some of it came off just from tapping it gently with my foot.

So that makes me think is this cars structure too compromised to be driven safely?

Since you live in Calgary, I would not put anymore money into this vehicle. It is very near to its end and is very likely compromised from a safety aspect. I would recommend to start looking for its replacement before it becomes inoperable or even fails catastrophically. The frame seems to be in much better condition than it should be based on the very significant body rust. I suggest you, or a mechanic, do a thorough inspection to determine how safe it is to keep driving on the roads.

 

[410Fortune]

The rear spring shackles and spring hangers need to be inspected closely,’rot in those areas will have you walk g or on your lid

 

[98FordLove]

The body has definitely lost a lot of strength due to the rot. It won't be able to proect against impact nearly as well as it should. It's definitely repairable by welding in new steel. I would also check where the body mounts attach to the frame as that area is super important safety wise.

Thanks. I'm guessing I'd have to get a welder to see what he would charge putting steel on the passenger side. Im guessing it's not cheap.

 

[Josh P]

The frame appears to be in a lot better shape than the body. The body can be cut and a replacement section welded in.

 

[98FordLove]

Frame still looks good.

Everyone has different tolerances when it comes to body rot. Frame rot is largely non-negotiable, so you’re looking good on that front.

Do you need me to get more pictures? The side rail, doesn't that hold the entire frame together?

Since you live in Calgary, I would not put anymore money into this vehicle. It is very near to its end and is very likely compromised from a safety aspect. I would recommend to start looking for its replacement before it becomes inoperable or even fails catastrophically. The frame seems to be in much better condition than it should be based on the very significant body rust. I suggest you, or a mechanic, do a thorough inspection to determine how safe it is to keep driving on the roads.

Yeah I was hoping to get 2 more years out of it then scrap it. But not sure if that will happen. Motor is still good though.

I'm thinking about taking it to another mechanic of mine to get him to fully check it out. I don't want to be driving a car that is not safe. I'm more worried about the winters here because the salt from the roads will hit that rust directly now that I don't have a side guard.

 

[98FordLove]

The frame appears to be in a lot better shape than the body. The body can be cut and a replacement section welded in.

Thanks. So the pictures that I took of that's the body and not the frame?

 

[Josh P]

Thanks. So the pictures that I took of that's the body and not the frame?

Correct. The frame is the steel rails in a bit. Can you post pictures of the frame at the rear leaf spring hangers?

 

[94Eddie]

Yeah I was hoping to get 2 more years out of it then scrap it. But not sure if that will happen. Motor is still good though.

I'm thinking about taking it to another mechanic of mine to get him to fully check it out. I don't want to be driving a car that is not safe. I'm more worried about the winters here because the salt from the roads will hit that rust directly now that I don't have a side guard.

To get more life out of it, assuming it is safe to drive, you can have it treated with a wax or oil based rustproofing like Fluid Film. What this will do is greatly slow the advancement of the rust. You can buy Fluid Film and apply it yourself but it leaves a mess where you do it. There are places that do this for a reasonable price.

 

[C420sailor]

Park on dirt or gravel when you do the fluid film.

The frame is that big C-channel that you see in the photo. The body sits on top of that.

People talk about impacts…and it’s certainly valid. I grew up driving around in jeeps and pickups with big holes in the floorboards, so I’m desensitized to some extent. I guess you just have to do a personal risk assessment—odds of a side impact based on your driving.

And even then, is it really going to make THAT much of a difference? That’s for you to decide.

As mentioned, inspect the entire frame and all the suspension components. Those are non-negotiable.

Me, personally? I’d drive it til the wheels fall off

 

[Josh P]

Park on dirt or gravel when you do the fluid film.

The frame is that big C-channel that you see in the photo. The body sits on top of that.

People talk about impacts…and it’s certainly valid. I grew up driving around in jeeps and pickups with big holes in the floorboards, so I’m desensitized to some extent. I guess you just have to do a personal risk assessment—odds of a side impact based on your driving.

And even then, is it really going to make THAT much of a difference? That’s for you to decide.

As mentioned, inspect the entire frame and all the suspension components. Those are non-negotiable.

Me, personally? I’d drive it til the wheels fall off

I was thinking the exact same thing.

 

[98FordLove]

Correct. The frame is the steel rails in a bit. Can you post pictures of the frame at the rear leaf spring hangers?

Okay I'll try. Is it possible to do this from the ground, just laying under the back?

 

[98FordLove]

To get more life out of it, assuming it is safe to drive, you can have it treated with a wax or oil based rustproofing like Fluid Film. What this will do is greatly slow the advancement of the rust. You can buy Fluid Film and apply it yourself but it leaves a mess where you do it. There are places that do this for a reasonable price.

Thanks. I picked some fluid film today and applied it on the passenger side. Boy it stinks but I'll accept it. Seems like a really good product that should last through winters here.

 

[Josh P]

Okay I'll try. Is it possible to do this from the ground, just laying under the back?

Correct, from a few angles. If the frame and suspension are sound, run it till it dies.

 

[J_C]

Me, personally? I’d drive it til the wheels fall off

This, but I'd drive slower on curves at high speed, where a failure and flipover is most catastrophic. I don't worry about collision protection, or else I wouldn't be driving a '98 full frame truck in the first place, decades later. I'm in the same situation with my '98, just rust not "as" bad yet... and I don't put a lot of miles on it, so my risk rate is reduced due to that.

As far as welding it up to repair the frame, I'd take a good hard look at everything, because by the time the frame is compromised, rust rot has probably compromised a lot more than just the frame. You need the frame for safety but you need the brake lines, fuel lines, floor panels, etc, for good reasons too. The rocker panels, meh they add structural rigidity but I wouldn't retire a 2nd gen based only on rocker panel collapse, because it is an old school full frame truck. On a frameless unibody vehicle, that is much sooner a death sentence.

 

[V8]

The rust in the rockers is mostly cosmetic. Do inspect the entire frame from front to rear with special emphasis on the suspension and body mount areas. My '01 only looks better at the rockers because my truck has the plastic rocker covers.

 

[vroomzoomboom]

thats mint for manitoba standards.

 

[wollimann]

Im guessing it's not cheap.

What is safety worth?
Both sides sheet + doglegs welding in Europe $2250 without paint.
Takes maybe 2 weeks.
2010 we had the same problem on both sides and we have no sunroof.
All 4 sunroof drains ending inside rocker rail, and the sheet is not very good rust protected.
Crazy construction!

Now in 2025 again a hole front passenger side.

You could protect the sheet inside area as much as you can with the best liquids on the market,
but you can't stop the rust.
But you can protect your own safety by regularly inspecting your car, in my eyes it is worth,
every $$$ you put in.
Regards Wolfgang