NHTSA Complaint #10507210 — 2004 LINCOLN AVIATOR

MY LINCOLN AVIATOR STARTED MAKING A HORRIBLE NOISE IN THE REAR OF THE VEHICLE ON THE MORNING OF SEPTEMBER 4, 2011. MY WIFE TOOK THE AVIATOR TO THE AAA CAR CARE CENTER TO FIND AND REPAIR THE ISSUE. THE AAA CERTIFIED TECHNICIAN PLACED THE AVIATOR ON THE LIFT AND DISCOVERED THE ENTIRE DIFFERENTIAL UNIT WAS HANGING FREELY AND LITERALLY SWINGING UNDER THE VEHICLE. AFTER FURTHER INSPECTION, THE WELDING THAT HOLDS THE MOUNT TO WHICH THE DIFFERENTIAL UNTIL IS BOLTED, BROKE FROM THE FRAME. THIS ISSUE OF A DIFFERENTIAL MOUNT WELD BREAKING FREE HAS NEVER BEEN SEEN BY THE AAA CERTIFIED TECHNICIAN OR THE AAA SERVICE MANAGER WITH OVER 30 YEARS OF EXPERIENCE. FURTHERMORE, THE MOUNT WAS ONLY WELDED ON ONE SIDE (SIDE CLOSEST TO THE REAR OF THE VEHICLE). I VISITED THE LOCAL LINCOLN DEALERSHIP AND EXPLAINED THE ISSUE WITH MY AVIATOR?S DIFFERENTIAL MOUNT ONLY BEING WELDED ON ONE SIDE AND ASKED TO SEE AN AVIATOR OR EXPLORER THAT WOULD HAVE THE SAME DIFFERENTIAL MOUNTING SYSTEM. THIS LINCOLN DEALERSHIP HAD AN EXPLORER UP ON THE LIFT AND SHOWED ME THAT THE DIFFERENTIAL MOUNT ON ALL AVIATORS AND EXPLORERS DO INDEED HAVE THE DIFFERENTIAL MOUNT WELDED ON BOTH SIDES TO THE FRAME. THE POTENTIAL DAMAGE FROM THE DIFFERENTIAL UNIT FALLING OFF THE VEHICLE AND THE DRIVE SHAFT BECOMING DISLODGED IS EXCEEDINGLY HIGH AND COULD POSE A FATAL SCENARIO. I AM ASKING FOR LINCOLN TO INVESTIGATE THIS POTENTIALLY FATAL ERROR OF ONLY HAVING ONE WELD SEAM HOLDING THE DIFFERENTIAL UNIT MOUNT TO THE FRAME AND INSPECT FOR ANY FURTHER DAMAGES AS A RESULT, IN ADDITION TO INSPECTING FOR OTHER AREAS OF FAULTY CRAFTSMANSHIP. THIS MANUFACTURING DEFECT IS IN NO WAY THE ERROR OF THE CONSUMER OR DRIVING BEHAVIOR. THIS ISSUE POINTS DIRECTLY TO THE CRAFTSMANSHIP AND INTEGRITY OF THE WELD AND QUALITY CONTROL OF LINCOLN. *TR