One problem related to frame rust has been reported for the 1997 Ford Explorer. The most recently reported issues are listed below.
I have seen several Ford Explorers ranging from years 1995-2001 that the frames are rusting through and breaking. I feel this is a serious safety issue. There is a severe rust problem with these frames and they appear to be manufactured quite thin to begin with. From what I have seen on over a dozen of these cars in my area, the frame is rusting through and breaking on the left rear corner anywhere from the front mount on the lr leaf spring to where the bumper mounts at the back of the frame. The cross member holding the body mounts is also rusting through in this area and coming into contact with the gas tank and also making the spare tire loose and at risk of falling out of the vehicle and becoming a hazard for following motorists. There is no good way to fix this problem and I feel that these vehicles should be recalled to get them off of the road. This is a very serious issue and I am not sure how there haven't been crashes and or deaths as a result of this very poor design and quality vehicle. Action needs to be taken immediately because from what I have seen this problem is just now starting to really take effect because of the aging vehicles.