Anyone know all the common areas for the 2nd gen frames to rust out? I know around the front sway bar is a common place. Anyone know of a good way to keep them from rusting out? I only have a little surface rust in places on my 95 and want to keep it nice so I’m going to respray it black as soon as it warms up. But don’t know how to keep the inside of the box frame where I can’t paint from rusting.

 

I recently had a rust out area on my '96 Ram 2500 4x4 frame just behind the passenger side mount for the front differential control arm. Also, replaced the riveted-in frame support that holds the front fuel tank strap directly under the rear of the cab.

A couple of years ago during the summer I treated the entire truck frame with a product called Zero Rust (https://www.zero-rust.com/zero-rust-products.html) to stop rust from spreading while I was swapping the 8 foot truck bed. Zero Rust that was applied to the frame is still holding up well.

Be sure to check the rear brake line - they love to rust out along the frame behind the rear portion of the fuel tank. I'm also in the process of replacing my 4WD steel vacuum lines, as they rusted out, too.

 

Where did you get that crossmember?

 

Apply Fluid Film or a Cavity Wax to the inside and treat the outside with a frame coating I used KBS

 

I picked it up from a local guy here that sells 2nd gen Dodge truck parts a few years ago. He had a stripped frame over there and I took a few cold chisels and a large hammer with me (to break loose the rivets that held the crossmember in-place) and took it off the frame. That crossmember came off a 2000 or 2001 frame and it was in mint condition - no rust whatsoever...

 

I didn't know if you found a place that sells them lol. Mine got some pin holes in it

 

https://www.eastwood.com/internal-fr...ay-nozzle.html

 

I’m going to pick up a few cans and try this. If it works good I will do it on my 11 and my 16 frame rails. Have you used this before?

 

I have and not a big fan

 

Funny you say this 'cause I just had a '00 on the lift that had been a PA truck most of its life and the worst area was the front sway bar mounts.

I don't recall anything else specific but the entire length of both framerails under the cab was pretty rusty, but not yet structurally compromised in my estimation. Then again we don't really get significant rust here in southern CO so what do I know.....