Hey everyone, Ive got a 99 Sport that has a leak somewhere on the driver side dash, and apparently its been there a WHILE, because when cleaning the Jeep today I noticed the carpet was REALLY wet and through the "hold down" tab that keeps the floor mat in place I could see SERIOUS rust. Ive got some heavy duty mats in the thing, those deep plastic/rubber ones, and I dont worry about water too much because I just take it out and dump it. My floor is never DIRTY because of the mats, so I dont usually spend much time messing around there. Looks like its been wet for years because its rotten through. Passenger side looks fine, etc., and so I decided I couldnt do any more damage and I cut up the carpet on the drivers side. There is a SERIOUS spot of rust there, like not much left, and when I touched it in one spot my finger went through. But the good news its contained to just the floor there. Im thinking about pulling out the whole carpet and checking it all out to make sure there arent any other issues.

Now, Ive been searching on line and I cant find ANY replacement panels for the '99, but I can find them for '84-'96 everywhere. Is the '99 a different animal? Does anyone have any experience doing this? Im pretty handy and Im sure I could get some 20 gauge sheet metal and form it and replace it myself, but I was thinking if I could find the whole front sheet for like $200 Id just buy it and replace the whole thing just in case, and so I knew it was all new.

If anyone can help me out Id REALLY appreciate it.

 

Nobody? Anybody?

 

I would cut the bad section out and patch it with some sheet steel.I have not really searched for formed replacement panels so sorry I cant help with that atm.

 

Does it look like this?



That's what the floor of my 1999 Limited looked like. I just bought the replacement panel, cut out that part of the floor, and had the new panel welded in. The floor panels are the same from 1984 - 2001.

Here is where I got mine from:

http://www.quadratec.com/products/72608_8500_07.htm

 

That sucks. Watch out for those interior leaks. The under carpet padding soaks up water. Floors are the same for all years EXCEPT the seat mounting cross member. 95+ they are raised.

Raybuck sells thicker than OEM replacement pans, pretty high quality.

 

yes the replacement panels a good idea but you really could have just used a hood, or a sheet of metal. that's what im going to be doing sometime in the next week or so to the jeep i am getting. so for no money just buying a drill i will cut the floor, cut a hood that my buddy has lying around and weld it in. it would save you the extra hundred plus shipping but if you don't have the tools around it is kind of hard to do...

 

I really appreciate the replies everyone.

Aerosynch, not THAT bad. Its rotten/rusted pretty bad, and Im sure I could put my finger through in some other spots, but I need to wait til mid June to tear it all apart. Thats when it'll be sitting idle for 3 months with nowhere to go and no worry.

I am thinking about getting some sheet metal and making them, but at the same time I saw a complete floor pan for like $190 and depending on what I find when I open it up all the way, I might want to just buy one whole stamped piece that will fit.

Which brings me to my most important question: I found a few places that had the whole sheet from the firewall to under the rear seat. They all say '84 - '96, which I thought was odd because I thought they were all the same up to 2000 or 2001.

So, when I tear out the carpet it might be, A: Make a piece for the small section I need to fix. B: By a whole stamped drivers side or, D: Buy a full sheet already stamped and replace the whole thing at once.

My other question is, are there any issue with the frame under there, i.e., do I need to weld it to the frame, etc. I dont have a welder but my buddy does and I have some experience and he has a ton, so welding isnt an issue, Id just like to know how deep Im getting myself in.

Also, the seat cross-member might be rusted too. Can I make those too or are they structural and easier to buy?

Like I said, any advice is really appreciated. Thanks!

PS: Anybody know any suppliers who sell replacement carpets?

 

i had a 1985 cherokee that had litterally no floor. i welded in all of drivers, front pass. rear pass. and the cargo area. the only part salvagable was about a 1ft by 2ft spot in the cargo area. it was bad.

 

go steel some mph signs and cut the old stuff out it will work fine

 

If you can find a Southern Junkyard who has an XJ, they will often cut out good sheetmetal sections & send it in the mail. We have loads of good floors @this yard: http://garysautowrecking.com/index.html

 

Had the same thing happen to my 96 where it leaked on the drivers side. It was caused by the top of the A-pillars rusting out which caused the windshield to leak. Look under the rubber around the top of the windshield of rust

 

I appreciate all the responses.

Yeah, I dont know where its leaking in from exactly. When I was looking around, I flipped the rubber pad over thats on the firewall under the pedals, and the back of it is a white foam. There was a wet black line down it right about where the break pedal is. Its leaking from somewhere up above there, because the day before we had torrential rain for like 3 hours. There is NO RUST on my Jeep (other than this) and I take VERY good care of her. I always was her off after mudding, dirt, etc., and I take real good care of her. Thats the odd thing: I cant imagine where this is leaking in from and why.

Anyway, I really appreciate all the info. Its helped me a ton. Im sure Ill have some more questions soon as Im planning on doing a bunch of stuff to her this summer anyway. THANKS!

 

I would check the main wiring harness grommet through the firewall above the brake pedal. That's a common leak area for the drivers side. I did a preemptive strike on it last year and sealed it engine side and cabin side with the "right stuff". <----- best sealer/gasket maker on the planet.

 

Seen this today Front floor pan,pair