NHTSA Complaint #10538142 — 2004 FORD EXPEDITION

MY TRUCK HAS STARTED MAKING A VERY LOUD NOISE COMING FROM THE FRONT UNDER SIDE OF THE VEHICLE. UPON FURTHER INVESTIGATION WE HAVE DISCOVERED THAT THERE WAS EXCESSIVE RUST AND CORROSION ON THE FRAME. THIS HAS CAUSED PARTS OF THE ENGINE TO SHIFT AND RUB/ COLLIDE WITH OTHER PARTS AND CAUSE THE NOISES. OUR MECHANIC AND MY HUSBAND BOTH FEEL THAT THE RUST AND CORROSION HAVE MADE THE VEHICLE UNSAFE TO DRIVE. THERE IS NO WAY TO TELL WHEN ANY PART OF THE ENGINE/VEHICLE COULD BREAK FREE, POSSIBLY CAUSING MORE DAMAGE AND OR AN ACCIDENT WHILE DRIVING. OUR VEHICLE IS VERY WELL MAINTAINED AND THE AMOUNT OF RUST AND CORROSION IS EXCESSIVE FOR THE YEAR AND MILEAGE ON THE VEHICLE. THE LACK OF ABILITY TO TELL WHEN OR WHERE THE FRAMEWORK MAY GIVE OUT MAKES IT UNSAFE IN OUR OPINION TO DRIVE. ESPECIALLY WITH CHILDREN IN THE VEHICLE MOST OF THE TIME. THE CORROSION IS ALSO SO EXCESSIVE WE BELIEVE IT IS NOT REPAIRABLE BY ANY BODY SHOP. MY FRUSTRATION WITH THIS IS THAT WE HAD NOT PLANNED ON GETTING A NEW VEHICLE AND WERE PLANNING ON DRIVING IT FOR QUITE AWHILE LONGER. OTHER THEN THE RUST AND CORROSION THE VEHICLE IS IN FAIRLY GOOD CONDITION.. I BELIEVE THAT THE RUST AND CORROSION SOUNDS VERY SIMILAR TO THAT DESCRIBED ON THE WINDSTARS AND SHOULD BE INVESTIGATED ALONG WITH THE WINDSTARS PROBLEMS. FINALLY THERE IS ALSO EXCESSIVE BUBBLING OF THE PAINT IN VARIOUS LOCATIONS OF THE VEHICLE.