NHTSA Complaint #724780 — 1997 FORD EXPEDITION

AT SLOW SPEED IN 4 WHEEL DRIVE GOING THROUGH A MUD PUDDLE, THE FLANGE THAT EXTENDS FROM THE REAR AXLE SHAFT ON WHICH THE DISC BRAKE CALIPER IS MOUNTED, BROKE IN SUCH A FASHION THAT THREE OF THE BOLTS FELL OFF RELEASING THE CALIPER TO FALL AGAINST THE TIRE. IN ADDITION, THE BRAKE LINE SEPARATED AND THE BRAKE FLUID RESERVOIR EMPTIED. THE PARKING BRAKE CABLE WAS ALSO SEVERED AND NONFUNCTIONAL. NO OBJECT WAS HIT TO CREATE THE PROBLEM AND WAS CONFIRMED BY THE FACT THAT THERE IS NO OTHER DAMAGE OTHER THAN THIS FLANGE. IT APPEARS, FOR NOW, THAT THE FLANGE CRACKED RELEASING THE DISC CALIPER ASSEMBLY WHICH THEN MUST HAVE ROTATED AROUND UNTIL THE BRAKELINE SEVERED. THE FAILURE OF THE FLANGE WOULD THEREFORE APPEAR TO BE A MANUFACTURING DEFECT IN THE QUALITY OF THE MATERIAL THAT MAKES UP THE FLANGE (WEAK STEEL?). WHAT MAY BE OF CONCERN IS A SIMILAR OCCURENCE AT HIGH SPEEDS