After rebuilding engine due to leaky headgaskets and replacing all 4 struts/springs and rotor/pads the rear cross member decided to throw in the towel. I did the work myself on the other stuff but i'm not too excited about about the newest issue. I bought the car 2 years ago as a beater specifically for the winter commute but I like it and its grown on the family.

 

What I need is advice about the hassle of replacing the rusted out bits. As far as I can tell its just the cross member and bar that connects the differential. All the bolts are extremely rusty and look like they'll break or at least have the heads flake apart.

 

I don't have a lift but can get access to one. How many hours of fun am I looking at and is it worth it? The car only has 97k on it and has had a bunch of stuff replaced but she's very rusty underneath and has rusty spots by the wheel wells.

 

Any advice about fixing or selling?

Pics could help, but if it's that rusted out that the bolts are bad, they're likely to snap and give you no end of grief trying to remove them.

 

Could be easier finding a less rusty but high-miles Forester/Outback with a blown HG and just swap in your fresh EJ251, part out your current one and make some money back...

Unfortunately that's a common problem with those years.

 

The bolts on those are actually pretty tough, the bigger problem is going to be if the captive nuts inside the body have rusted. If the welds on those break the nut will just spin with the bolt then you have to cut a hole in the floor to get access to the nut. If the car is heavily rusted you might be better off to find a car with less rust and swap your suspension and engine.

is that considered a 'suspension' part?

 

there's a recall that might be related check over at cars101.com

Thanks for your replies. I checked on the recall and the original owner had it "rust proofed" at her local dealer in 2003. I was assuming it was considered part of the frame although it provides connection points for some of the suspension in the rear.

I hadn't thought of the nut stepping out in the frame. That might seal her fate. Thanks again.

Thanks for your replies. I checked on the recall and the original owner had it "rust proofed" at her local dealer in 2003. I was assuming it was considered part of the frame although it provides connection points for some of the suspension in the rear.

I hadn't thought of the nut stepping out in the frame. That might seal her fate. Thanks again.

Not a big fan of after market rust proofing by a dealer or anyone else. It just does not do much to prevent rust. Don't think much rust proofing is applied to the frame members, or suspension parts.