NHTSA Complaint #10225772 — 2000 FORD F-250 SD

I WAS DOING SOME REPAIR WORK ON MY FORD F-250 AND DECIDED TO LOOK AROUND THE UNDERSIDE. I WAS STUNNED TO SEE THAT 2 OUT OF 4 LEAVES OF THE LEFT REAR SPRING HAD BROKEN OFF NEAR THE U BOLT. THE PROBLEM WAS NOT EVIDENT WHILE DRIVING BECAUSE I HAVE NOT PUT ANYTHING HEAVY IN THE TRUCK. I ONLY FOUND THE PROBLEM BECAUSE I WAS PREPARING FOR A LONG TRIP WITH A HEAVY TRAILER. THE TRUCK WAS AT MY FORD DEALER THE WEEK BEFORE AND THEY DID NOT NOTICE THE BROKEN SPRING. WHILE SHOPPING FOR A REPLACEMENT SPRING, I WAS AMAZED HOW MANY STORES MADE COMMENTS LIKE "WE SELL A LOT OF THESE". I CALLED THE FORD CUSTOMER SERVICE LINE TO ASK THEM TO PAY FOR THE REPAIRS AND THEY CLAIMED THAT THEY DO NOT GET ANY REPORTS OF BROKEN SPRINGS. I AM A DEGREED MECHANICAL ENGINEER AND AM REASONABLY FAMILIAR WITH THE DESIGN OF SPRINGS. I FIRMLY BELIEVE THAT NO SPRING SHOULD EVER FAIL UNDER NORMAL USE. HAD THE SPRING FAILED WHILE I WAS ON THE ROAD, I WOULD HAVE LOST CONTROL OF THE TRUCK. MY INFORMAL DATA COLLECTION TELLS ME THAT MOST OF THE FAILURES HAPPEN AFTER THE WARRANTY EXPIRES. IT APPEARS THAT FORD HAS NO WAY TO KNOW ABOUT REPAIRS MADE BY NON-FORD SHOPS. GIVEN THAT THE PRICE DIFFERENCE FOR THE REPAIR IS SUBSTANTIAL, IT WOULD BE REASONABLE TO SUGGEST THE MOST OF THE REPAIRS ARE MADE OUTSIDE OF FORD. THE CUSTOMER SERVICE REP WAS NOT INTERESTED IN THE SAFETY ASPECT AND TOLD ME THERE WAS NO OTHER WAY TO CONTACT ANYONE ELSE IN THE COMPANY. IN MY BEST ENGINEERING JUDGMENT, THE SPRING FAILED DUE TO FATIGUE. THE PROBLEM IS MUCH LARGER THAN FORD REALIZES. AND ALL OF THE VEHICLES WITH THESE SPRINGS ARE GETTING OLDER EVERY DAY. I WAS NOT KILLED OR INJURED BY THIS DEFECT ONLY BECAUSE OF MY ENGINEERING AND MECHANICAL ABILITIES ENABLED ME TO SEE AND FIX IT BEFORE IT FAILED. *TR