Two problems related to frame rust have been reported for the 1997 Ford F-150. The most recently reported issues are listed below.
I have a 1997 Ford F-150, I was changing the front brake pads and noticed a lot of rust on the frame and basically every thing else under the body. I took a screwdriver and pushed it all the way through the suspension travel stop. There are big chunks of rusty metal falling off of it at least every three or four months apart. I can take my finger and push through the front bumper. All the bolts on the exhaust manifolds and collectors are rusted off or all most rusted off. To fix the exhaust it will cost around $700. 00, if the dealer done the repairs it would cost much more. The gas tank straps looks real rusty also. In my 54 years of life I have never seen a frame and the underside of a vehicle rust so bad. I live in the south so the truck did not see much salt.
The contact owns a 1997 Ford F-150. The contact stated that the spare tire cable, exhaust system manifold, fuel tank strap, brake line, bolts, erg valve, and the frame were rusted. The vehicle was not repaired. The manufacturer was made aware of the failure and denied to buy the vehicle back or provide any assistance. The failure mileage was 220,000 and the current mileage was 322,000.