NHTSA Complaint #10808666 — 2004 FORD ESCAPE

OUR 2004 FORD ESCAPE IS MAKING METALLIC CREAKING, SQUEAKING AND GROANING SOUNDS FROM THE PASSENGER SIDE REAR. THE SOUND IS TRIGGERED BY JUST SITTING IN THE STATIONARY CAR AND ROCKING BACK AND FORTH. IT BECOMES CONSTANT AS SOON AS THE VEHICLE STARTS MOVING. THERE ARE ALSO OCCASIONAL HEAVY METALLIC THUMPS OR KNOCKS ON THE PASSENGER SIDE OR UNDERSIDE OF THE CAR, AND THE RIDE IS ROUGH. THE PASSENGER SIDE REAR INNER METAL WHEELHOUSE IS EXTREMELY RUSTY. A FEW HOLES ARE SEVERAL INCHES SQUARE & GO ALL THE WAY THROUGH INTO THE INTERIOR OF THE CAR. PART OF THE RUST IS VERY NEAR WHERE THE TOP OF THE SHOCK ABSORBER BOLTS INTO THE WHEELHOUSE. THE WHEELHOUSE METAL IS SO RUSTY THAT I CAN FLEX IT WITH MY HAND AND CAUSE THE CREAKING SOUNDS. I BELIEVE THE HEAVY METALLIC THUMPS ARE CAUSED WHEN THE CONICAL BUMPER INSIDE THE TOP OF THE SPRING BOTTOMS OUT AND HITS THE SUSPENSION MOUNTED TO THE BOTTOM OF THE SPRING. THIS LIKELY HAPPENS BECAUSE THE SHOCK ABSORBER CANNOT STOP IT, SINCE THE RUSTY WHEELHOUSE BENDS SO MUCH. THIS SERIOUS SAFETY PROBLEM IS HEAVILY DOCUMENTED ON THE INTERNET BY A VERY LARGE NUMBER OF PEOPLE. THE TOP OF THE SHOCK ABSORBER COULD CRASH THROUGH THE WHEELHOUSE AND PROTRUDE INTO THE CAR INTERIOR, INJURING OCCUPANTS OF THE CAR. THIS WOULD MAKE LOSS OF CONTROL MORE LIKELY. IT WOULD BE EXTREMELY DANGEROUS IF THE SHOCK ABSORBER BREAKS FREE AND BECOMES TANGLED UP WITH THE REAR WHEEL OR PUNCTURES THE TIRE. THIS CAR IS A UNIBODY CONSTRUCTION, SO THIS WHEELHOUSE IS SUPPOSED TO PROVIDE STRUCTURAL STRENGTH FOR THAT PART OF THE CAR. IN THE EVENT OF A CRASH THIS RUSTY WHEELHOUSE WILL DISINTEGRATE AND NOT PROPERLY ABSORB THE CRASH ENERGY LIKE IT IS SUPPOSED TO. THIS MAKES IT MORE LIKELY THAT THE OCCUPANTS WILL GET INJURED. PLEASE FORCE A VEHICLE RECALL ASAP WHICH MAKES FORD MOTOR CO. REPLACE THIS DANGEROUS WHEELHOUSE WITH ONE THAT HAS A SAFER, NON-RUSTING DESIGN.