NHTSA Complaint #11638533 — 2006 FORD ESCAPE

The idler pulley on the subject vehicle has failed numerous times, with the mounting bolt shearing at the connection to the timing cover. Upon failure of the pulley the serpentine belt will either fail or become dislodged; when this occurs the steering, alternator, and water pump all stop operating. The vehicle becomes difficult to handle due to the loss of power steering, and is subject to shutting off due to the lack of an alternator and water pump. This particular issue has happened to me on four separate occasions in the last two years; the first time occurred while operating in traffic; the subsequent occasions were noted during startup and were detected before driving. New replacement pulleys will only last approximately 4000-5000 miles before they fail. The power steering pump and air conditioning compressor have been replaced due to concerns that they could be placing extra strain on the serpentine belt, however the issue has occurred even after replacing these components. Internet research notes that this is a common problem of the 2.3L engine in the Escape and other Ford/Mercury models of the same time frame. Nobody has reported a permanent solution; later model vehicles using the same or similar issue came equipped with electric power steering, which likely reduced the load on the pulley and its undersized mounting bolt. The idler pulley on this vehicle has proven to be an Achilles heel and should have been addressed by Ford via a recall and redesigned pulley.