Core support/radiator support rust at frame??

[cdherman]

Anyone else have this in the 03-06 trucks?

My 04 has very little rust at all, BUT up front, where the core/radiator support sits on the rubber pads between it and the frame -- the core support is flakeing off, with deep rust and damage. Only real rust on the vehicle...

I was under the vehicle getting ready for winter and it really bothered me. I knew about it when I bought it, but its progressed in a year quite a bit.

The core support has not yet sagged or collapsed, but it worries me how long that will take.

Anyone else notice this?

Getting it appart to blast it and repaint would essentially entail taking the whole front clip off the truck. A nightmare.....

Whole chunks of rust and paint falling off. Strange.....

 

[sgtowing]

It's happening on mine as well. I figure ill wait and save to replace it when it gets worse. Im hopping being in Fl now instead of Mi will considerably slow the process

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[cdherman]

Well, it really troubles me -- clearly a design flaw of some sort, since there's so little rust elsewhere.

I looked things over some more. Looks like when it starts to actually collapse, the core will drop to the frame about 1.5" below. I might be able to jack it up and stick a 2x4 in there and keep things junkin' along. But sure is not what I'd hope for......

 

[Rod240sx]

I've noticed the same thing on my 06... It's the only heavy rust in the vehicle.

 

[Dexter]

I sanded and repainted it once I noticed a little spec of rust forming

 

[Rod240sx]

Hi Guys,

Long story short, I had to bring my 2006 Limited to the body shop to fix some minimal damage (got side-swiped while parked). When they removed the front bumper, they noticed severe rust on the lower portion of my radiator support/core support. It was a bit of a surprise to me since I had noticed rust in that area before from underneath the vehicle, but had no idea it was this bad.

From framerail to framerail, the entire lower core is disintegrating in my hands. I could literally poke a hole with my finger in certain areas. Such a disappointment - loosing a radiator should not be a concern on a 6 year old truck.

Keep an eye on that area of your vehicles!

I'm waiting for a quote from the bodyshop on replacing the core/radiator support. I'll update shortly..

 

[Big White]

Pics would be great! I went VERY liberal with rust cop in that area when I was spaying.

 

[GAINMOB]

well you are in kansas and everyone but dexter is in a northern/snow climate...my truck is from florida and im in virginia now...i dont have any

 

[Big White]

Pics of the corrosion damage if you can please!

 

[kmh1596]

I have the same damage, and knew about it when I bought the truck. I found a shop that quoted ~$500 to replace the radiator support. I'll be bringing it in this winter.

The damage to mine is shown below. Sorry they are not zoomed out at all, but it was what the seller sent me before I drove out to look at the truck.

 

[RAWPWR]

was changing my left side burnt out fog light and saw all this rot on the frame above the rubber mount. checked the right side and the same! how hard is it to replace this "core support/ radiator support" part of the frame? special tools??

 

[ExpeditionAndy]

was changing my left side burnt out fog light and saw all this rot on the frame above the rubber mount. checked the right side and the same! how hard is it to replace this "core support/ radiator support" part of the frame? special tools??

It is an involved process. You have to remove the front bumper, grille, and fenders, Then the condenser and radiator and the oil cooler and trans cooler if equipped. Then you have to cut off the rusted parts and weld in the new radiator support. I'm not equipped to do it so I'll be taking mine to the body shop for them to do it.

 

[speedrich]

Exact same situation here. Northern Quebec truck being eaten by salt and sh*t on the road over the winters. Very low rust elsewhere. Will be getting that fixed too hopefully around spring...

 

[RAWPWR]

thanks ExpeditionAndy , what about replacing the entire unit, are there welds that need to be cut and then rewelded? I'm guess there is. bolt on would be great. thanks again
here's a pic of one side of mine..

 

[ExpeditionAndy]

thanks ExpeditionAndy , what about replacing the entire unit, are there welds that need to be cut and then rewelded? I'm guess there is. bolt on would be great. thanks again
here's a pic of one side of mine..

Here is an excellent thread on the subject: http://www.expeditionforum.com/f41/truck-going-surgery-tomorrow-19719/#post156190

 

[RAWPWR]

awesome, thanks again!

 

[65comet]

Just to put it out there, mine is almost gone too. And, the tranny coolant lines where they pass under it on the drivers side rusted away and blew this weekend. Some supplier skipped something on those supports.

 

[ExpeditionAndy]

Just to put it out there, mine is almost gone too. And, the tranny coolant lines where they pass under it on the drivers side rusted away and blew this weekend. Some supplier skipped something on those supports.

Put your year and model in your signature.

What year Expedition do you have?

 

[65comet]

I saved the year in the profile when I set it up. Didn't notice it doesn't show that on the page like some of the other forums I'm in. Wonderful '05 (slightly sarcastic). I have two heavy boxes in the garage with new cam phasers to put in. I think just about everything else that is known to go bad has done so. Next Summer this one is going and I'm investigating 2009 and 2010 for a replacement. Just too much they didn't do right on this one to keep it for another 10 years. And fixing this rust support would be too much time that I would rather spend on something I love instead of something that is just for getting the family, dogs around and for camping.

 

[foredeckguy]

Has anyone located an aftermarket radiator support for the 2006 Expy? A couple months ago I searched and could only find the Ford part for lots of money.