NHTSA Complaint #10493505 — 2005 FORD EXPEDITION

WHILE TRAVELING DOWN THE FREEWAY AT 70 MPH, THE VEHICLE DIED. IT WOULD NOT RESTART. AFTER 1 HOUR VEHICLE THE VEHICLE STARTED AND THEN DIED WITHIN SECONDS. THE FUEL FILTER AND FUEL PUMP WERE REPLACED BECAUSE ALL INDICATIONS LEAD TO BELIEVE THAT THE FUEL PUMP WAS BAD. AFTER REPLACEMENT OF THE FUEL PUMP, VEHICLE WOULD NOT START. LOOKING ON THE INTERNET FOR POSSIBLE SOLUTIONS FROM OTHERS, I FOUND ONE PERSON WITH THE SAME PROBLEM AND FOLLOWED THEIR ADVISE ON HOW TO FIX IT. I FOUND THE "DRIVERS MODULE" ON THE BACK TOPSIDE OF THE FRAME. WHEN THE MODULE WAS REMOVED, IT WAS FOUND TO HAVE TWO LARGE SECTIONS OF CORROSION ABOUT 1/4 INCH THICK. WHEN THE CHUNKS WERE KNOCKED OFF, UNDER THEM WERE TWO HOLES THROUGH THE SIDE OF THE MODULE AND THE CIRCUIT WAS BURNT, THE PLUG WAS ALSO STARTING TO CORRODE. THE PLACEMENT FOR THE MODULE IS A TERRIBLE SPOT. IT IS ALUMINUM ATTACHED TO A STEEL FRAME, WITH NOTHING SEPARATING THEM. WHEN THE NEW MODULE ARRIVED, IT NOW HAS A RUBBER GASKET TO KEEP THEM SEPARATE. THIS LOOKS LIKE A DESIGN FLAW ON FORD'S PART AND A RECALL SHOULD BE ORDERED. FORD SHOULD FURTHER REFUND THE COST OF THE FUEL PUMP BECAUSE ALL INDICATIONS SHOW THAT THE FUEL PUMP IS BAD, WHEN IN TRUTH IT IS THE MODULE AND NOT THE FUEL PUMP. *TR