NHTSA Complaint #10299125 — 2003 FORD EXPLORER

THE PLASTIC APPLIQUE BELOW THE REAR WINDOW OF 2003 FORD EXPLORER CRACKED IN COLD WEATHER. THE VEHICLE WAS NOT IN MOTION. IT CRACKED WHEN THE REAR DEFROSTER CIRCUIT WAS ACTIVATED. INTERNET RESEARCH INDICATES THIS IS A WIDESPREAD PROBLEM, POSSIBLY AFFECTING 10-20% OF VEHICLES MANUFACTURED. IT IS CLEARLY A DESIGN PROBLEM. FORD, IN IT'S INFINITE WISDOM, GLUED THE LARGISH PLASTIC TRIM PIECE DIRECTLY TO THE REAR GLASS. IN COLD WEATHER, WHEN THE DRIVER ACTIVATES THE REAR DEFROSTER, THE GLASS EXPANDS AND THE PLASTIC TRIM PIECE, STILL EXPOSED TO THE COLD DOES NOT. THIS UNEQUAL THERMAL EXPANSION RESULTS IN THE PLASTIC APPLIQUE PIECE CRACKING. THIS IS A PROBLEM THAT SHOULD HAVE BEEN EASILY FORESEEN BY DESIGN ENGINEERS. IN TALKING WITH LOCAL FORD BODY REPAIR SHOPS, THE STAFF ADMITTED THAT THE ISSUE IS WIDESPREAD. THE REPAIR COSTS ABOUT $500. *TR