NHTSA Complaint #10716450 — 2007 FORD EXPEDITION

MY STEERING SHAFT LOCKED UP ON THE HIGHWAY. I ALMOST COULD NOT TURN THE VEHICLE. IT TOOK MUCH FORCE TO BREAK IT FREE. MADE IT HOME AND STARTED TO DIAGNOSE IT. FIRST, I THOUGHT THE RACK & PINION FAILED. BUT IT TURNED OUT TO BE FINE. IT APPEARS THAT THE STEERING INTERMEDIATE SHAFT IS THE FAILURE. THIS IS THE PARTS BETWEEN THE STEERING COLUMN AND THE RACK & PINION. I REPLACED IT WITH FORD PART NUMBER 8L1Z-3B676-A. THIS NEW PART APPEARS TO BE A REDESIGNED SHAFT FROM FORD. I RESEARCHED THE INTERNET A LITTLE WITH SIMILAR PROBLEMS. THEIR APPEARS TO BE MANY ASSOCIATED WITH THE SAME FAILURE. I BELIEVE THE U-JOINTS IN THE SHAFT AND ITS MATERIAL SELECTION ON THE ORIGINAL PART TO BE THE PROBLEM. THE NEW SHAFT IS A MORE ROBUST DESIGN AND APPEARS TO BE OF A DIFFERENT GRADE OF METAL. MY CONCERN IS THAT IT TOOK MUCH FORCE FOR ME TO BREAK THE STEERING LOCK UP. IT COULD HAVE BEEN A VERY BAD INCIDENT AND AFTER MY RESEARCH. IT APPEARS THAT FORD IS AWARE OF AN ISSUE AND REDESIGNED A PART FOR A FIX. I KNOW THAT MY WIFE COULD NOT BEEN ABLE TO BREAK IT FREE GOING DOWN HIGHWAY. I HAVE THE OLD PART SAVED AND WOULD BE GLAD TO SENT IT TO YOU FOR YOUR REVIEW. I'M CONCERNED THAT MILLIONS OF THESE VEHICLES ARE ON THE ROAD AND COULD POTENTIALLY LEAD TO MANY UNNECESSARY COLLISIONS. EFFECTS 2004-2011 F-150'S & EXPEDITIONS.