'02 Wrangler X Rust Nightmare: Looking for Advice

NicholasC1988

New Member
Original poster
Joined
Jul 30, 2019
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8
Location
Aurora, IL
Hey Guys,

I have been following this forum for a long time, but this is my first time posting..

I have always dreamed of owning a Wrangler. I preferred the TJ's short wheelbase and everyone's builds over the newer models. I hoped to buy one with the intention of building it up over the next few years. I bought the car of my dreams about 8 months ago. I just got a new job, was trying to find a place to live and needed a car right away. In the past I only bought cars off of craigslist, but I thought going with a dealer would be a safer bet (especially with a TJ I had been fantasizing over for years). My lust of being a TJ owner and the immediate need for a DD overthrew my better judgement during the buying process. Instead of putting my research into buying the Jeep I was focused on what I wanted to do to the TJ after I got it. The inside floors looked good when I pulled up the carpet and the frame was painted black. I overlooked a lot of warning signs I have now seen throughout these posts. This Wrangler X was a manual and had 80K with the 4.0 engine I wanted to start out with. I thought that this would last me a couple years as a DD until I could buy a truck to focus on building up the Wrangler. In the first couple weeks of owning the car I had to replace the rusted out front sway arm connectors. I called the dealer after my inspection (which I should have done in the first place) turned up some pretty bad rust. Their response was that I should have looked at the car closer when I purchased. A week later I popped out and replaced the steering box because I came out to my TJ was leaking power steering fluid. I've done a few other common things that have come up throughout the months. My embarrassment of my findings have kept me from posting on this forum to date. Before the winter I took off any visible rust with a wire brush and RP'd the hell out of it to try to make it through the winter. . During the winter I got underbody car washes often as possible to try to keep the situation from getting worse. My wife and I just bought our new house last month so my eye was off the ball. After getting screwed on the Jeep I wanted to make sure I thoroughly researched a house, mortgages, etc. I really didn't realize how screwed I was until a couple weeks ago. The skid plate looked to be sagging a little, but on the way home when I realized it was sagging it rusted out, and hung about 4" from my driver side frame. I started wirebrushing the paint on the frame I realized the dealer had painted over the worst of it to make it look better than it was. I'm still making payments on the Wrangler so I am looking for the best advice to stop from making a terrible situation worse. I have a car I can borrow for a couple-few months so I bought myself some time. Below is after wire brushing the paint off the frame.

A shop owner told me the Jeep is totaled. He let me keep the Jeep in his parking lot with the skid plate jacked up for a week while I tried to figure out my next move. He said the dealership did a pretty good job of prettying the car up, but I doubt its anything I can prove at this point.

I found a custom welder who was weary about taking on the job. I told him I would do whatever it takes to fix it. I would drop the fuel tank and give him side by side pictures of what other jeeps with the condition looked like compared to what mine looked like. I've seen some videos of this getting fixed, but not sure if I'll be so lucky.

I was hoping I could bring the welder the floor support, safeTcap, rear coil spring bracket, and small lift.
When I researched what dropping the fuel tank entailed I was optimistic I could take on the job. Unfortunately there is rust at the top of the rear coil and spring bracket. I wanted to replace these anyway with a 2" Old Man Emu Kit.

If you're reading this you probably have already seen the links below..

https://www.autorust.com/product/full-length-floor-channel-subframe-set-wrangler-tj-97-06/https://www.autorust.com/product/wrangler-tj-full-center-section-with-rear-trail-arm-mounts/
I know I need new brake lines, and I took out the exhaust mount when I was checking for rust..

That puts me at 2640 + another 1000 of best case scenario "other random things I find" before I start putting in labor (hoping for the best 1500 if I remove the gas tank first?). That puts me at 5140 best case to do the job. Scrapping it puts me at something like 2k-3k so putting in that money seems like a good option if it takes care of the problem.

The only other way out would be to find a high mileage TJ in Illinois with a good frame and switch out the engine. I figure it will be a fat chance of finding that type of TJ near me. After looking for a thread where someone switches out one 4.0 for another it seems like I should just buy a new engine if I go through the trouble of pulling one out. Looking at the Jeeps around seem like I would be looking at investing at least 6k to find something like that.

I have some pictures below after I wire brushed the bubbling paint. if I could get some input, other big problems you can see that I am missing, or threads that might help me out..

I have too embarrassed about my situation to post up until now so any advice is appreciated..

Rear Driver Side

1564541469651.webp


Middle Driver Side
1564541528950.webp


Between the manual transmission and the skid plate

1564543246317.webp


Front driver side looking down

1564543282996.webp


front driver side

1564543337212.webp


Here's where I got my numbers..

850frame rails
390floor channel
102spring bracket relocation
9302" Old Man Emu Kit
108Brake Lines
260skid plate
1000Other things
1500Labor
5140
 
How did you pay for the Jeep? Credit card by chance?

No doubt that thing is basically totaled from an insurance perspective. It's certainly not safe to drive by any means.
 
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How did you pay for the Jeep? Credit card by chance?

No doubt that thing is basically totaled from an insurance perspective. It's certainly not safe to drive by any means.

Yeah right.. Insurance won't consider it a total loss otherwise my gap insurance would cover it. I'll see what happens though, if I can fix it will make for one hell of a thread. I've seen some videos and threads of some guys conquering some pretty rough stuff.
 
Yeah right.. Insurance won't consider it a total loss otherwise my gap insurance would cover it. I'll see what happens though, if I can fix it will make for one hell of a thread. I've seen some videos and threads of some guys conquering some pretty rough stuff.

While I can only see what is in the photos, chances are if that frame is rusted that bad in those locations, the entire frame is rotted out and needs to be replaced (this is the case more often than not).

That being said, having a frame replaced isn't cheap. @jodomcfrodo had his entire frame replaced by a local shop with a clean, rust free frame. I can't remember what he paid, but it's upwards of 6k if I remember correctly.

And that's not factoring in any potential body rust if it exists.

A clean frame is about $1500-$2000, but then you factor in the cost of labor (it's a massive project), replacing other things while you're in there (since you'd be silly not to), and you can easily understand why it costs as much as it does.

It blows my mind that there are shady dealerships out there like this. It should be illegal to sell a vehicle like that, as it genuinely is not safe to drive on the road.

I'm not kidding when I say if I was in your shoes, I would 100% be contacting a lawyer and finding out if you have a case against them. You very well might, and a free consultation with a lawyer would be worth it in a situation like this.

Often times under the threat of legal action, a dealership will settle outside of course and make things right.
 
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I can't put it all on them though. It was a real oversight and lack of research on my part.

Oversight or not, that car shouldn't have been for sale on any dealer lot unless the rotted frame was disclosed. It's not safe for road travel and could end up killing you or someone else had you been unlucky.
 
I can't put it all on them though. It was a real oversight and lack of research on my part.
Yeah but they knew and that's the issue. Sadly not the first jeep I've seen sold like this. @Chris remembers the red one that showed up at my work with new temp tags and a control arm brace patch welded on.
 
What a bunch of bastards to sell you a Jeep like that. It looks like they did a fairly good job of covering it up too. Looks like they even painted the driveshaft. Not many people would have noticed any signs of the condition of the frame. I'd definitely talk to a lawyer first, but if that doesn't come through then I'd look into safety caps. There are plenty of shops around Illinois that have done them before since half the Jeeps around here need them.
 
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Ouch.

Its an interesting thread and I am here to see how it plays out. Since you have had it for so long already I am not sure what a lawyer can do, but I am not in law so maybe there is something they know that I dont. Instead of sinking $5400 into I would cut my losses and buy something else for the interim and look into a jeep later down the road once you have your housing for sure squared away and any other life events have settled down.
 
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While I can only see what is in the photos, chances are if that frame is rusted that bad in those locations, the entire frame is rotted out and needs to be replaced (this is the case more often than not).

Here I go, maybe I'm crazy, who knows.

Chris is right about the chances, but I'd check to see where those chances take this one.

The bottom of that frame is as bad as I've ever seen. Parts of it aren't even there. All that rust comes from two things, 1) salt and other stuff collecting up on the inside and 2) salt and other chemicals soaking in between the frame and skid plate. The rest of the frame gets less of the first and almost none of the second.

The rest of the frame may, or may not, be OK. In those pictures I don't see any rust holes near the control arm mounts or any factory holes that have grown in size due to rust. The floor doesn't seem to have any rust holes either. I'd tap all around with a hammer and see what's left.
 
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I feel bad for you- it has happened to me as well. The problem with an attorney is that they don't work for free and you might end up spending a few thousand to get a refund. Throwing good money after bad never pays off, so if the insurance company gives you something reasonable it might be better to just cut your losses.
 
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Also... the lawyer thing. They offer free consultations and can tell you if you have any legal ground for a lawsuit. I'm not kidding, that's honestly the first thing I'd do.

If that dealership gets a letter from a lawyer, I can almost guarantee they'll buy the vehicle back from you or make it right.
 
I don't have access to all my TJ bookmarks on my work pc but there's complete galvanized NEW frames for sale online. I'd be going that route if you're attached to the Jeep and can't get any legal recourse.
 
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I don't have access to all my TJ bookmarks on my work pc but there's complete galvanized NEW frames for sale online. I'd be going that route if you're attached to the Jeep and can't get any legal recourse.

There are disadvantages to those frames that aren't immediately obvious. I went with a stock frame under mine to avoid them.
 
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What you posted is fixable. As you've seen, they make replacement prefabbed portions of the frame that are easy enough for a competent shop weld in. I just had something similar done to the body where one of the mounts rusted out. My frame was thankfully still in great shape.

The bigger (and most costly issue) is that if your frame looks that bad there, it likely looks just as bad elsewhere. Sure you can go on replacing section by section as it rusts out, or just replacing the entire frame all together, but the question is if it's worth it in the end. If you put in $10k into frame work, you're unlikely to get that return back. Your other option is to pick up a physically great Jeep that's mechanically bust and fix it up using the parts from this Jeep, selling off what you don't need to help recoup the costs. Yes, it's going to cost you some, but I think in the long run it might cost you less, and you'll wind up with a Jeep that's in a better (and more valuable) condition.
 
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