NHTSA Complaint #10342406 — 1998 FORD EXPEDITION

I HAD A CATASTROPHIC FAILURE OF THE REAR SUSPENSION ARMS ON MY 1998 FORD EXPEDITION. I WAS TRAVELING AT A SLOW SPEED WHEN THE ARM SNAPPED WITHOUT WARNING. HAD THIS SUSPENSION ARM BROKEN AT HIGHWAY SPEED, THE RESULT WOULD HAVE BEEN A LIFE THREATENING WRECK. THE REAR END ROLLED UP CAUSING THE VEHICLE TO BE IMMOVABLE , REQUIRING A TOW FOR REPAIRS. AN INSPECTION REVEALED, THE UPPER SUPPORT ARM FOR REAR THE SUSPENSION RUSTED COMPLETELY THROUGH, CAUSING THE ARM TO BREAK. THE OTHER UPPER ARM IS RUSTED THROUGH BADLY, AND BOTH LOWER ARMS ARE RUSTED THROUGH BADLY. ALL THE ARMS WERE READY TO BREAK. I AM SURE THIS FAILURE IS THE FAULT OF (1) POOR ENGINEERING AND DESIGN BY FORD (2) POOR SELECTION OF GRADE OF STEEL USED IN MAKING THESE ARMS (3) POOR QUALITY CHECKS, IF THESE ARMS DID NOT MEET SPECIFICATION. THERE IS NO WAY A PART AS ROBUST AS THIS NEEDS BE, SHOULD EVER BE ABLE TO RUST THROUGH! I WROTE TO FORD AND HAVE NOT GOTTEN A SATISFACTORY RESPONSE AT THIS TIME. I HAD REPAIRS MADE BY A HIGHLY QUALIFIED MECHANIC. WHILE HE WAS OBTAINING PARTS HE FOUND THIS FAILURE WAS BECOMING MORE COMMON. BOTH UPPER AND LOWER ARMS WERE REPLACED. ONE AIR BAG HAD TO BE REPLACED AS IT WAS PIERCED BY THE BROKEN ARM. I HAVE THE OLD PARTS IN MY POSSESSION. THIS WAS A FRIGHTENING AND VERY EXPENSIVE REPAIR ,THAT FORD IS RESPONSIBLE FOR ! MY FORD EXPEDITION IS IN GOOD SHAPE AND HAS BEEN WELL MAINTAINED, IT IS NOT A "BEATER". UPDATED 07/30/10 *BF UPDATED IVOQ 08/03/10.*JB *TR