Another rusty Pathfinder frame

[01PathLE]

New member here, first post, and hopefully not the last... 2001 Pathfinder LE, 215K miles, bought it new, runs great, no major issues. Took off front wheels to change brakes and found a bad rust issue on the passenger side. Pretty sure the AC condensation was the reason, pictures were taken after a short ride on a hot day, and there was water seeping out of the rust holes. Same spot on the driver side is perfect.










While researching possible fixes I found out about the frame rust recall. All of 16 years the Pathfinder was on the east coast/New Jersey, so it has seen plenty of road salt. Took pathy to dealer, unfortunately the strut housings are OK and this spot is not covered. I called a few repair/body shops, no one wants to touch rotted frames. I already got my money out of the Pathfinder and then some, but would hate to junk a perfectly running SUV because of one rusty spot. Rest of the frame has some surface rust but not as bad as this. Expensive repairs are not an option, the pathy also needs new brakes, tires, and has a minor RMS leak.

I guess I'm looking for opinions of what my options are. Junk it? Sell it with full disclosure? Try to fix it? I have friends that are good welders and would work for beer, but does anyone sell frame sleeves or brackets that could be used in this spot? Anyone had luck getting a dealer/Nissan honor the recall for other parts of the frame?

Thanks in advance.

[barnaclebob]

If it were me, I'd by on the way to the Toyota dealership to trade it in for a new 4runner, but then again I've had my eye on a 4runner for awhile now. Especially since you will need other maintenance and tires soon. That doesn't look easy to repair and is a pretty critical location. It could be fine for years or you could hit a pot hole or do an emergency turn and it could break.

Do your welder friends have experience with car frames? If they really are good welders I'd be surprised if they didn't cringe at this but you may as well ask them about it.

[MisterH]

The problem anyone would be facing by attempting a fix is the expense that the RIGHT method would entail. This is not a casual 'patch it together in the garage" weekend project. Such radical repairs require a modern, laser alignment frame rig. Doing it without that will certainly result in a frame misalignment and a car that will never track straight.

[Hawairish]

I disagree with the last assessment. The suspension is on a completely independent subframe, which appears intact. The lower control arm bolts to the subframe, and the subframe bolts to the unibody chassis. If the subframe is compromised, a donor subframe makes for simple repair. The chassis point can be reconstructed and boxed with steel plate and weld-in nuts. The point is one of four attachment points for the subframe, so the corners of the mounting 'rectangle' are already defined well for 3 of those 4 points. All four points are completely flat, roughly 2"x5.5" pads with two threaded inserts (14mm rear, 12mm). You'd just need to ensure there's enough usable steel beyond the rusted spot to weld plate onto.

Getting the subframe down is a task in itself. Having done a few subframe drops, including full measurements of all the mounting points and suspension parts, I'm pretty familiar with this.

[Hawairish]

Scratch my "appears intact" comment about the subframe. Pic didn't load right on my phone I guess.

In that case, the subframe is likely compromised, but that can be replaced with a donor. The chassis will need some work as previously described.

[01PathLE]

BanrancleBob, I'm already looking at 4Runners, just trying to figure out which model:) No trade in, the Pathy was supposed to be a gift to my daughter, who was born the year (and the reason why) we got it. But I'll need to make sure it's perfectly safe before that.

Hawairish, thanks for your suggestions. Plan now is to get the 4runner and keep the pathfinder as a winter project. I'll visit a few junkyards to look for availability and pricing of donor parts, and then take off the subframe. If there is too much damage and it can't be fixed, I'll junk it then.

Just to get an idea, assuming the frame issue is fixed the right way, what's a typical lifespan of the powetrain on these pathfinders?

[barnaclebob]

I've seen them go well into 200k but mines only at 152k and runs very well. At 215k your issues would be a death sentence for just about anyone.

The key is to not let problems pile up to the point where it doesn't seem worth it to repair them. Having to get new tires alone might make sense but new tires along with a few weekends of suspension bushing, fluid replacement, and sensor troubleshooting can make it feel like you should junk the car.

I've been eyeing the trail premium or I guess they changed it to the TRD off road package or something. A new model generation is rumored for 2018.

[01PathLE]

I picked up a new 4Runner TRD Pro, so now I can take my time working on the frame repair. Where is the best place to look for frame diagrams/part names/numbers for a 2001 pathy? I looked online, but can't find anything specific. Having part numbers would help locating donors at local junk yards. Would FSM's have part diagrams, and also any help with removing sub-frame?

[cr4west]

Get that R50 way up in the air on jack stands with double support. Drop the lower "A" arm and the sway bar to get all the rubber bushing(s) safely out of the way. Remove sub frame if necessary. Mounting bolts that do not turn cut off and carefully drill out to preserve the threaded blind nuts. Use eye protection, a grinder, air impact chisel or hammer with a cold chisel and your strong arm to remove the rust compromised metal areas back into solid good metal. If possible try to leave the big blind nut for the suspension bolt in place on some of the original metal for position reference. Grind all the edges clean 1/2" and box it back in using suitable grade sheet steel with a wire feed welder. Go for strong not beautiful. I would use an oxy acetylene torch and a hammer to heat and gently form the patch plates into position as you wire feed weld. Use water soaked rags and sheet metal shields to protect the surrounding areas. Acrylic or urethane exterior house sealant with a putty knife to seal it up, paint and undercoat. Re-assemble, fix the AC water drain problem and enjoy.

[atraudes]

I picked up a new 4Runner TRD Pro, so now I can take my time working on the frame repair. Where is the best place to look for frame diagrams/part names/numbers for a 2001 pathy? I looked online, but can't find anything specific. Having part numbers would help locating donors at local junk yards. Would FSM's have part diagrams, and also any help with removing sub-frame?

Try poking around the parts section on http://www.nissanpartsdeal.com. They're my favorite place for parts that I've found so far, and they have excellent diagrams. I saw some frame pieces in the "Member & Fitting" section, though didn't see the shock towers anywhere. You could always drop them a line and see what they say.