DII Rust Hole in Frame (under passenger cat)

[p-dawger]

IN doing some searching this seems like a common issue. What are people doing to fix this? My rust hole is about the size of a quarter...does not seem like a structural issue, now but its pretty rusty and not sure what it looks like inside...

What are folks doing to contain this? I was going to clean up best I can and then use some rust converter to slow things down.

I guess major surgery would be to cut out the effected area and weld in a plate.

Just wondering how bad this could get without attention.

Mine has 200k on it - northern VA winters.

 

[DarylJ]

To clarify....it's either got to be NEXT TO the cat (if it's on the frame), or it's really on the (removable) crossmember (under the cat).

Which is it.....because it makes quite a big difference.

 

[crown14]

Ive seen next to the cat before, maybe he means that.

 

[The Fourth Amigo]

I had this problem. I removed the hardware from y-pipe/cats and cross member myself. I also disconnected the O2's. The exhaust was held on by one nut at each manifold and I replaced the bolts at the muffler. I then brought it to a welding shop and had a proper job done. No overlap. They put the exhaust back loose and I finished the job at home.

 

[btp98w]

I had this problem on my 2000 D2 also. Got a new frame from LRNA under my extended warranty.

If you can't get that done, just weld in a patch.

 

[RoverbyProxy]

The only real way to get rid of rust is to cut out the area weld in new, prime, and paint.

There are several products out there that will "convert" the rust but how well it works is questionable. Chassis Saver is one and I think another is made by Magnet Paints

 

[capri_auto]

I had this problem on my 2000 D2 also. Got a new frame from LRNA under my extended warranty.

If you can't get that done, just weld in a patch.

how you pull this off, and in what year? Maybe I'm just dreamin but I'd love a new frame hahaha

 

[p-dawger]

Sorry it's next to the cat that is what I meant....

Would love to hear the new frame story....

Is this just for certain years that have the issue or all Disco II's - Did the later years put some kind of protector next to the cat.

Never heard of any disasterous frame issues - I am sure there are a number of these running around out there like this....