2004 Ford Expedition Suspension Problems

RUSTED OUT ROCKER PANELS, BRAKE LINES, FRONT END RADIATOR MOUNTS, FENDER MOUNTS. THE ENTIRE UNDER CARRIAGE IS RUSTING AWAY. WE HAVE HAD TO REPLACE ALL THE BRAKE LINES AS THEY HAVE RUSTED AWAY, REDID THE ROCKER PANELS RUST AWAY. NOW WE HAVE TO REPLACE THE ENTIRE FRONT END BECAUSE OF RUST. WILL NOT PASS PA STATE INSPECTION DUE TO RUST. IS THE EXPEDITION IN THE RECALL FOR RUST?

I NOTICED THAT MY SUV WAS STARTING TO RIDE A LITTLE ROUGH. A MONTH LATER IT STARTED TO RIDE A WHOLE LOT ROUGHER. I SAW THAT MY TIRES ON THE FRONT END WERE WEARING ON THE INSIDE TREAD. THEN THE WHOLE FRONT END STARTED TO SHAKE WHILE DRIVING. I TOOK IT TO A GATEWAY AND THEY TO LD ME THAT IT WAS MY TWO FRONT LOWER BALL JOINTS ON THE SUV WERE BAD AND NEEDED REPLACING. I DON'T UNDERSTAND WHY THE TRUCK WAS RIDING SO SMOOTH AND ALL OF A SUDDEN THE LOWER BALL JOINTS GO BAD. *JS

MY TRUCK HAS STARTED MAKING A VERY LOUD NOISE COMING FROM THE FRONT UNDER SIDE OF THE VEHICLE. UPON FURTHER INVESTIGATION WE HAVE DISCOVERED THAT THERE WAS EXCESSIVE RUST AND CORROSION ON THE FRAME. THIS HAS CAUSED PARTS OF THE ENGINE TO SHIFT AND RUB/ COLLIDE WITH OTHER PARTS AND CAUSE THE NOISES. OUR MECHANIC AND MY HUSBAND BOTH FEEL THAT THE RUST AND CORROSION HAVE MADE THE VEHICLE UNSAFE TO DRIVE. THERE IS NO WAY TO TELL WHEN ANY PART OF THE ENGINE/VEHICLE COULD BREAK FREE, POSSIBLY CAUSING MORE DAMAGE AND OR AN ACCIDENT WHILE DRIVING. OUR VEHICLE IS VERY WELL MAINTAINED AND THE AMOUNT OF RUST AND CORROSION IS EXCESSIVE FOR THE YEAR AND MILEAGE ON THE VEHICLE. THE LACK OF ABILITY TO TELL WHEN OR WHERE THE FRAMEWORK MAY GIVE OUT MAKES IT UNSAFE IN OUR OPINION TO DRIVE. ESPECIALLY WITH CHILDREN IN THE VEHICLE MOST OF THE TIME. THE CORROSION IS ALSO SO EXCESSIVE WE BELIEVE IT IS NOT REPAIRABLE BY ANY BODY SHOP. MY FRUSTRATION WITH THIS IS THAT WE HAD NOT PLANNED ON GETTING A NEW VEHICLE AND WERE PLANNING ON DRIVING IT FOR QUITE AWHILE LONGER. OTHER THEN THE RUST AND CORROSION THE VEHICLE IS IN FAIRLY GOOD CONDITION.. I BELIEVE THAT THE RUST AND CORROSION SOUNDS VERY SIMILAR TO THAT DESCRIBED ON THE WINDSTARS AND SHOULD BE INVESTIGATED ALONG WITH THE WINDSTARS PROBLEMS. FINALLY THERE IS ALSO EXCESSIVE BUBBLING OF THE PAINT IN VARIOUS LOCATIONS OF THE VEHICLE.

WAS DRIVING WHEN BRAKES WENT COMPLETELY OUT WHEN I WENT TO STOP AT A STOP SIGN. . CAUSE DUE TO RUST CORROSION . BRAKES GIVING OUT COULD HAVE CAUSED A FATAL CAR ACCIDENT . RUST HAS DAMAGED ALL BRAKE LINES AND FUEL LINES . RUST IS NOW MOVING UP THE VEHICLE. BRAKE LINES AND FUEL LINES SHOULD HAVE A PROTECTED COATING OR MADE WITH A NON CORROSION METAL. I HAD NO IDEA THAT MY BRAKE LINE WAS RUSTED OUT TILL MY BRAKES GAVE OUT. THESE VEHICLE NEED TO BE RECALLED AND HAVE NEW LINES. ALSO HAVE A PROTECTED COATING APPLIED UNDER THE VEHICLE TO STOP RUST. VERY VERY DANGEROUS DRIVING AROUND NOT KNOWING THAT YOU HAVE RUST UNDER YOUR VEHICLE EATING AWAY AT YOUR BRAKE LINES AND FUEL LINES. *TR

I BOUGHT FORD EXPEDITION WITH AIRBAGS SUSPENSION AND NOW IT'S BROKEN LIKEWISE AIR COMPRESSOR TOO WAS DAMAGES ,WHICH I DIDN'T KNOW OR ANY IDEA THEY SOLD ME THIS SUV, LOADED WITH THIS AIRBAGS SUSPENSION, IS IT LEGAL HERE IN HAWAII TO SOLD CARS OR SUV'S LOADED WITH AIRBAGS SUSPENSION ? *TR

PERFORM FOUR WHEEL ALIGNMENT. NOW I'M TOLD THAT THE FRONT END BARS ARE BENT AND THE CAMBER OUT OF SPEC. HAD TRUCK FOR THREE YEARS AND ONLY REPAIR IS FROM BEER HIT RIGHT FRONT. DEALER TELL ME THAT IT FROM POT HOLDS IN THE STREET. *TR

TL*THE CONTACT OWNS A 2004 EXPEDITION. WHILE DRIVING 25 MPH THE TORSION BAR SNAPPED UNDER THE VEHICLE AND THEN THE REAR AXLE PULLED THE DRIVE SHAFT FROM THE TRANSMISSION. THE VEHICLE WAS TOWED TO A AUTO REPAIR SHOP. THE DEALER NOR THE MANUFACTURER HAVE BEEN CONTACTED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 104,000.

TL*THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THE COMPRESSOR HAD BEEN FAILING EVER SINCE THE VEHICLE WAS PURCHASED. ON MAY 11, 2008, WHILE THE VEHICLE WAS PARKED, THE SUSPENSION DROPPED AND THE REAR OF THE VEHICLE WAS RESTING ON THE REAR TIRES. THE SUSPENSION FAILED WITHOUT WARNING. THE VEHICLE HAS NOT BEEN INSPECTED BY A DEALER OR MECHANIC. THE CURRENT AND FAILURE MILEAGES WERE 72,153.

SEPTEMBER 24, 2004, I WAS DRIVING MY 2004 FORD EXPEDITION [XXX] IN HENDERSON, KENTUCKY. I PURCHASED THE VEHICLE IN JULY FROM D-PATRICK FORD IN EVANSVILLE, INDIANA. I WAS HEADING EAST TO PICK UP MY SON AT APPROXIMATELY 2 PM. ON HIGHWAY 60. THANKFULLY, I WAS IN SLOW TRAFFIC AND HAD STOPPED DUE TO A TURNING VEHICLE IN FRONT OF ME, AND WAS PROCEEDING TO GO AROUND THIS VEHICLE WHEN THE INCIDENT OCCURRED. SUDDENLY MY STEERING WHEEL WAS JOLTED AND IT FELT AS THOUGH MY PASSENGER SIDE FRONT WHEEL HAD FALLEN OUT BENEATH ME, AND I WAS BROUGHT TO A HALT. UPON GETTING OUT OF MY CAR, IT LOOKED AS IF THE TOP HALF OF THE TIRE HAD FALLEN INTO THE VEHICLE. THE SMELL OF BURNING RUBBER WAS APPARENT. A FEW MINUTES LATER, I WOULD HAVE BEEN ON US HIGHWAY 41 WITH MY SON TRAVELING 60 MPH. THE INJURIES AND DEATHS THAT COULD HAVE OCCURRED TO US AND OTHERS ON THE ROADWAY ARE VERY DISTURBING TO ME. *AK THE TOW OPERATOR AND THEN THE SERVICE MANAGER WHERE THE VEHICLE WAS FIRST TOWED (CLOSEST DEALERSHIP), DEMPLEWOLF FORD IN HENDERSON, INFORMED US IT WAS A DEFECTIVE BALL JOINT. THE VEHICLE WAS TOWED AGAIN TO D-PATRICK FORD IN EVANSVILLE, INDIANA, ON SATURDAY, SEPTEMBER 25, IN ORDER TO GET THE REPAIR MADE AND OBTAIN A LOANER VEHICLE. I KNOW THAT THIS IS A DEFECT IN THE PRODUCT AND I WANT ACTION TO PREVENT OTHERS FROM GETTING HURT OR KILLED. I WAS A LUCKY, BUT IF THERE IS ONE LIKE MINE, THERE ARE OTHERS. I AM CERTAIN I WOULD HAVE ROLLED OVER DUE TO THIS MALFUNCTION IF I WAS TRAVELING AT A HIGHER RATE OF SPEED. EVEN AT MY LOW RATE OF SPEED, THE STEERING WHEEL CONTROL WAS IMPACTED AND I FELT IN DANGER. I AM CONCERNED FOR MY FAMILY AND OTHERS SAFETY. HAVE TOLD THE DEALERSHIPS AND WRITTEN TO THE BOARD OF DIRECTORS OF FORD MOTOR COMPANY ASKING THEM TO REPORT THIS TO YOUR ORGANIZATION. I HAVE HEARD FROM NO ONE. I FEEL THIS IS AN IMPORTANT AND URGENT MATTER THAT NEEDS TO BE INVESTIGATED.*AK UPDATED 07/27/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

WHILE DRIVING VEHICLE MADE A LOUD POPPING NOISE AND VIBRATED. TOOK VEHICLE TO DEALER FOR SERVICE THREE TIMES, AND DEALER INFORMED CONSUMER THAT THIS WAS NORMAL.*AK