Rust problems around Fuel Door on '96 4 Door

[BlueOvalProud]

Has anyone else had a serious rusting problem around the gas doors of 90's vintage Explorers? I do and haven't seen any others like it. My '96 spent the first 8 years of its life in Kane, PA where I think they lay salt down 8 months of the year! An exageration but you get the idea. The problem started last fall with little bubbles forming in the paint forward of the gas door. It has progressively gotten worse to the point where I have now punched a few holes through the sheet metal with a screwdriver. I pulled off the access panel to the rear windshield washer tank and removed it. The inner fender is also rusted where it contacts the fender.

I have two possible scenarios here' The NWPA salt has gathered where the wheelhouse and the plastic inner fender meet the fender. There is quite a bit of spongy foam here, presumably meant to prevent rattles but more than likely an excellent breeding ground for rust.
OR
The overflow out of the WW tank from overfilling has leaked out. I have used the heavy duty ww solvent, the brand that melts ice at -20 degrees! Since you don't know you are full until the solvent runs out the filler pipe, perhaps the solvent anti-freeze is corrosive.]

OR a combination of both scenarios.

Two questions:

• Has anyone else had this problem?
• Does anyone know of a source for a repair panel?
  

Thanks,

Bob in Stamford CT

 

[Hoppy]

All first and second generations ex's have this problem. What you have to do is every time you get the chance through the winter is flush out that area with a hose and make sure you oil coat it with some form of rust control oil.

I have done this on my 92, 97 and 00 explorers and have not experienced any rusting of that area.

Bad design because the wheel kicks up sand and salt, it sits on top of the plastic housing that holds the filler cap in place. After time it will rust. Keep it clean and oiled and you shouln't have any trouble, but other than that, you sound like you have to replace all the metal there.

 

[quicklook2]

about 70 to 80% in ohio have at least some rust, some have it real bad.

national parts depot or lmc makes a replacement panel.

 

[BlueOvalProud]

Thanks for the sources for panels. NPD doesn't have any repair panels fpr Explorers that I could find and LMC 's panels only go to '94. Not sure if they are compatible. I will probably go the fiberglass route on the inside of the fender and bondo to fill in the outside.

 

[Millertime1987]

It is also problem here in MN. My parents explorer is getting the cancerous spots around the fuel door as well. Going through the big chain places they quoted close to 600 bucks. They may still look around but they know its something that happens in MN so they will probably get a newer car anyway. Theres is a 98 4.0 not sure if its the SOHC or OHC.