NHTSA Complaint #10220549 — 2003 FORD EXPLORER

TL*THE CONTACT OWNS A 2003 FORD EXPLORER. WHILE DRIVING 60 MPH, ON FEBRUARY 17, 2008, THE ENGINE SHUT OFF IMMEDIATELY WITHOUT WARNING. SEVERAL VEHICLES WERE RAPIDLY APPROACHING THE CONTACT, WHICH NEARLY CAUSED A FATAL CRASH. THERE WERE NO WARNING LIGHTS PRESENT PRIOR TO THE FAILURE; HOWEVER, AFTER THE ENGINE SHUT OFF, ALL OF THE LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC AND DIAGNOSED. THE MECHANIC WAS UNABLE TO RESTART THE VEHICLE. THE DEALER DIAGNOSED THE VEHICLE AND STATED THAT THE CATALYTIC CONVERTER NEEDED TO BE REPLACED. THE PART WAS ORDERED AND MAY BE AVAILABLE BY NEXT WEEK. THE VEHICLE HAS BEEN AT THE DEALER FOR TWO WEEKS. THE MANUFACTURER'S PRESIDENT WAS NOTIFIED ON TWO OCCASIONS AND THE SECRETARY FORWARDED THE MESSAGES TO A LIAISON. THE CONTACT WANTED THE VEHICLE REPLACED, BUT THE LIAISON STATED THAT SHE COULD NOT ASSIST. THE CONTACT SAW ON THE NEWS THAT THERE WAS A MANUFACTURER'S RECALL AND FILED CASE NUMBER 0490000518. THE MANUFACTURER STATED THAT THERE WERE NO EXISTING RECALLS RELATED TO THE FAILURE. THE FOLLOWING FAILURES OCCURRED WITH THE PREVIOUS OWNER: ON MARCH 1, 2004, THE RING AND PINIONS FAILED, ON MARCH 31, 2004, THE PINION VALVE LEAKED, WAS DAMAGED, TESTED AND REPAIRED. ON APRIL 14, 2004, WHILE DRIVING APPROXIMATELY 55 MPH, THE FRONT PINION SEAL WAS LEAKING AND REPLACED. THE UPPER BEARING WAS ALSO REPAIRED. THE VIN APPEARS TO BE INVALID. THE FAILURE AND CURRENT MILEAGES WERE 40,000.