NHTSA Complaint #11527007 — 2006 FORD ESCAPE

This 2006 Ford Escape Hybrid, and all first and second generation (2001-2012) Escape models, were designed and built with a significant, known defect in the mating area and materials used for the rear floor pan, rear sub-assembly/rails, and rear inner fender liners/upper shock absorber mounts, all made of pressed steel. The design of the components renders them subject to trapping road debris/salt/contaminants, and the inferior steel used oxidizes quickly, resulting in perforated areas of substantial rust. In our 2006 model, the right rear inner fender liner was completely replaced, and the rear subassembly/rails were welded, in 2013 with new Ford parts. By May, 2018, it had to be repaired and welded again. As of May, 2013, five years almost to the day, it has again rusted and separated. As this hybrid Escape carries a 600 pound battery between the rails in the rear of the vehicle, this is a substantial, dangerous defect affecting potentially millions of cars manufactured over a decade. The current status of the oxidation, corrosion, rot and decay affecting our Ford Escape has rendered it incapable of being repaired per the auto mechanic shop we visited first, followed by the body shop we visited next. Both indicated that the poor design combined with the steel used contributed to the dangerous vehicle it has become.