I also have an '05 Pacifica and the sub frame is beginning to rust. This problem was brought to my attention by a friend who also has a Pacifica. I checked with Chrysler and there is a service bulletin on this for '04 and '05s. If you haven't already, check with your local dealer and see if your VIN is on the list. I was told mine is not, but I am not giving up yet on getting some assistance from Chrysler. I was also told by an independent mechanic that there may be a class action suit announced by the spring. Hope this gets you some help on your repair.