Suggestions on dealing with body mount rust

Mikester86

Mikester86

If at first you don't succeed, skydiving isn't 4 U
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Dec 6, 2018
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Michigan
My TJ is a 2001 Sport. I believe it has only seen 2 Michigan winters. I purchased it earlier this winter and it will be our warm weather toy, stored winters as it is now.

Today being warmer out, I was able to snap some photos of some problem areas around the body mounts. These 2 are on the drivers side below the door.

Feeling inside of the frame holes, is smooth, which is a good sign. When the weather warms, I plan on scraping and grinding/sanding the rust areas and probably hitting them with some Klean Strip phosphoric acid.

I will clean and scrape all the bad areas up as much as possible. After that, it should give me a better look at what is left and how solid. I would like to spray with the Klean Strip as well, but do not want to hit the actual rubber mounts.

I am not sure why these particular body mount areas got hit so hard, as the rest of the frame and body mounts are in good shape.

I welcome all suggestions and comments!

Thanks for reading!

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Wow, that's nasty!

If it was the frame, you could cut out a section of it and replace it with a Safe-T-Cap or similar. However, that's the actual body itself, so it's tougher.

Perhaps someone like @Mike_H or @toximus will have a better and more knowledgable answer. I say that because those guys have dealt with more rust like this than I have.
 
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Thanks Chris! I’ll clean it up the best I can and hope enough left is solid and can be protected going forward.
 
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You will need to cut and re-weld those body mounts into the torque tube. That metal is too far gone. I'd buy something like this

https://www.autorust.com/product/floor-support-torque-box-art-145-2-r-passenger-side/
Which looks similar to what you've posted, but its one complete piece. Hope you know how to weld...probably be an expensive job at a body shop.

Also, you've got some "non-standard" hardware going on in that top picture. Shouldn't be any extra washers in there.
 
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Mike_H said:
You will need to cut and re-weld those body mounts into the torque tube. That metal is too far gone. I'd buy something like this

https://www.autorust.com/product/floor-support-torque-box-art-145-2-r-passenger-side/
Which looks similar to what you've posted, but its one complete piece. Hope you know how to weld...probably be an expensive job at a body shop.

Also, you've got some "non-standard" hardware going on in that top picture. Shouldn't be any extra washers in there.
Click to expand...
I used to weld, but it’s been a long time. I do however know a pro that retired from Ford that has a shop! 😁
 
Mike_H said:
You will need to cut and re-weld those body mounts into the torque tube. That metal is too far gone. I'd buy something like this

https://www.autorust.com/product/floor-support-torque-box-art-145-2-r-passenger-side/
Which looks similar to what you've posted, but its one complete piece. Hope you know how to weld...probably be an expensive job at a body shop.

Also, you've got some "non-standard" hardware going on in that top picture. Shouldn't be any extra washers in there.
Click to expand...
With the "non standard" hardware, I can only assume someone altered it as a "fix". Always something! :(
 
Hey guys! I'm new here, looking into purchasing a 97 sport this weekend, it has this same problem. My question is if I got the jeep is this something that should be repaired asap or something that can wait awhile? I can weld buuut I don't have a welder at the moment and they're spendy.
Here's the jeep....
00x0x_kHZG8wXwBFd_1200x900.jpg

...annnd here's the problem😕
IMG_3146.jpg
 
Lets look at it this way. Granted that is only one mount, but it is very bad. If the others look the same or close, you are asking if you can drive for a while and fix later. Well you are setting inside the body that the mounts hold to the frame. If the mounts are bad what is holding you and the body to the frame? I would check the frame in all the known bad spots, because I cannot believe the mounts are that bad and the frame is good.
 
Check out Classic Enterprises for their replacement boxes. I used one on my 99 tj. Its a pain to replace.
 
Yeah after further investigation I'm not gonna bother with that one, 3 of the mounts are visible rotted through so im sure the others are on the inside
 
sparkyhooker said:
Yeah after further investigation I'm not gonna bother with that one, 3 of the mounts are visible rotted through so im sure the others are on the inside
Click to expand...


Yup walk away. Look somewhere in my region to purchase. We have very little to no rust issues west of me in the desert states. I know it's a lot of work but it will never be more work to fly to Arizona than it will be to work on a rusty rig.
 
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HELP. I need advice. I want to get this 97 TJ but I’m not sure the body mounts are safe? Should I steer clear? How long can I drive this before it gets too unsafe?

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