NHTSA Complaint #10454791 — 2001 FORD EXPLORER SPORT TRAC

THE RISING PRICE OF GAS DISCOURAGED ME FROM USING MY SPORT TRAC (ST) OFTEN, SO IT WAS GARAGED DURING THE WORK WEEK. ON THE WEEKENDS, I USUALLY DROVE THE ST TO RUN ERRANDS AROUND TOWN. ON JAN 28, 2012, I DROVE LESS THAN A MILE WHEN MY ST BEGAN LOSING THROTTLE RESPONSE AND AN UNFAMILIAR CLATTERING CAN BE HEARD GENERATED IN THE ENGINE BAY. I QUICKLY REALIZED THAT THIS WAS NOT NORMAL, SO I PROCEEDED TO PULL OVER. I THEN TOOK THE TRUCK TO A MECHANIC NEAR MY LOCATION. THE MECHANIC AFTER EXTENSIVE DIAGNOSIS DETERMINED THAT THE TIMING CHAIN TENSIONER HAD FAILED, ALONG WITH TIMING CHAIN GUIDES WHICH SHATTERED INTO MULTIPLE PIECES (PHOTOS AVAILABLE). THE TIMING CHAIN AND ITS COMPONENTS ARE SUPPOSE TO LAST FOR A LIFETIME OF THE VEHICLE, AND HENCE FORD PROVIDED NO INFORMATION OR PROVISION FOR ITS MAINTENANCE. THE REPAIR WAS EXPENSIVE, BECAUSE IT REQUIRED THE REMOVAL OF THE ENGINE WHICH IS BASED ON THE SOHC DESIGN HAVING ITS RIGHT CAMSHAFT DRIVEN BY A TIMING CHAIN LOCATED BEHIND THE ENGINE NEAR THE FIREWALL. A RECALL OF THE TIMING CHAIN GUIDES AND TENSIONER SHOULD BE MADE BECAUSE OF THE COMMON PROBLEM THIS HAS BEEN FOR THIS ENGINE DESIGN, SOHC 4.0L AFTER THE REMOVAL OF THE ENGINE AND TIMING CHAIN GUIDE REPLACEMENT, MY VEHICLE BEGAN TO EXPERIENCE TRANSMISSION FAILURE. THE TRANSMISSION REGISTERED AN ERROR ON MY DASHBOARD, AND AFTER CONSULTATION WITH AN EXPERT, REQUIRED A TRANSMISSION REBUILD. THE COST OF THE ENGINE AND THE TRANSMISSION REBUILD HAS BEEN VERY EXPENSIVE TO SAY THE LEAST. THE UNPREDICTABLE NATURE OF THIS FAILURES WOULD COMPROMISE SAFETY DURING HIGH SPEED OPERATIONS. I HOPE NHTSA WILL REVIEW COMPLAINTS REGARDING TIMING CHAIN AND TRANSMISSION FAILURES, WHICH SHOULD REVEAL A PATTERN OF DESIGN FAILURES AT FORD. INTERESTINGLY, FORD HAD ISSUED A RECALL FOR THE TIMING CHAIN TENSIONERS AND ENGINE REMOVAL TO REPAIR CHAIN GUIDES IN THE PAST. *TR