NHTSA Complaint #10251204 — 2003 MERCURY SABLE

MY WIFE ASKED ME TO CHECK THE STRANGE NOISE IN HER CAR WHEN SHE STARTED TO BACK OUT OF OUR DRIVEWAY ON THE MORNING OF DECEMBER 8, 2008. I REMOVED THE RIGHT FRONT WHEEL EXPECTING TO SEE WORN OUT BRAKE PADS. INSTEAD, THE WHEEL STARTED TO MOVE TOWARD ME WHEN I BEGAN REMOVING THE LUG NUTS. THE COIL SPRING WAS BROKEN INTO TWO PARTS. FORTUNATELY, IT BROKE OVERNIGHT AND DOESN'T APPEAR TO HAVE DAMAGED THE TIRE. TIME WILL TELL WHETHER OR NOT IT WEAKENED THE INNER SIDEWALL OF THE RIGHT FRONT TIRE. FAILURE ANALYSIS OF THE 28 CM LENGTH OF SPRING BROKEN OFF FROM THE LOWER END OF THE SPRING IS AS FOLLOWS: THE BROKEN CROSS-SECTION OF THE SPRING HAS A DARK RUST SECTION, ABOUT 15 MM CIRCUMFERENTIALLY AND 2 MM RADIAL FROM THE EXTERIOR SURFACE. THE EXTERIOR SURFACE OF THE SPRING IS RUSTED WHERE THERE IS NO LONGER ANY PROTECTIVE BLACK COATING NEAR THE DEFECTIVE CROSS SECTION. THIS SURFACE AREA IS ABOUT 25 MM CIRCUMFERENTIALLY AND 15 MM LONG FROM THE FRACTURED CROSS SECTION. THERE ARE ABOUT 4 RADIAL FRACTURE LINES EMANATING FROM THE BOTTOM SIDE OF THE SPRING STARTING AT THE 15 MM X 2MM RUSTED AREA. THERE APPEARS TO BE PINPOINT RUST AREAS THROUGHOUT ABOUT 70 PER CENT OF THE REMAINING CROSS SECTION, BY MY NAKED EYE. I WILL BE REPLACING THE COIL SPRING TODAY OR TOMORROW, EITHER MYSELF OR AT A GARAGE. THIS APPEARS TO BE THE SAME TYPE OF FAILURE AS RECALL NUMBER 04N-332. THIS DEFECT IS ONE OF THE REASONS WHY I AM LAID OFF. I HAVE BEEN A FRICTION MATERIAL ENGINEER FOR OVER 25 YEARS. NO WONDER AMERICANS HAVE STOPPED BUYING AMERICAN AUTOMOBILES. THIS MERCURY VEHICLE HAS BEEN MUCH BETTER THAN MY DODGE VEHICLES UP UNTIL NOW. *TR