2001 Ford Expedition: ball joint or control arm failure

Filed Feb 19, 2016 · Suspension · 101,500 miles · IL · crash · 3 injuries

Rear upper and lower control arms completely rusted out, resulting a dangerous driving situation. I have vehicle serviced regularly at a ford dealer and was never informed of such a hazard. While driving, heard a loud noise and felt a bad jerk, rear-end just fell down. Had severe medical issues as result. Ford needs to alert consumers of this problem and implement a recall, before a fatal occurs.

Filed Mar 13, 2015 · Suspension · 208,000 miles · IL

Tl* the contact owns a 2001 ford expedition. The contact discovered that the rear lower control arms/trailing arms were completely rusted. The contact was a certified mechanic who replaced the lower control arms. The manufacturer was not made aware of the failure. The approximate failure mileage was 208,000. Updated 4/30/15*cn the consumer stated the passenger side was rusted too, but was still intact. Updated 05/07/15

Filed Feb 13, 2015 · Brakes, Electrical · 125,000 miles · OR

This has been an issue since acquiring this vehicle. The brakes are very soft, they will pump up but when a quicker slow down or stop is needed an individual doesn't have a lot of time to remember that. There have been no injuries or crashes as of this date. Master cylinder was replaced on mechanic's advice however this did not improve this issue. As well the vehicle seems to need the lower ball joints wear out quickly. Also please note that each time it rains there is water coming in from somewhere on the top driver's side of the windshield and post. It drips from that hand grip down to light switch and into vent on driver's side as well. There have been times where there is an electrical smell which causes concern of a vehicle fire possibility.

Filed Jul 11, 2013 · Engine, Suspension · 127,510 miles · MA

I was stopped at a red light, and all of a sudden I heard this loud crash and bang, and was jerked forward. Thought the pick up truck behind me rear-ended me. That driver pulled up aside of me and told me you just dropped your driveshaft. Since it was dark and my vehicle was in the middle of the road at an intersection I called the police. When they arrived they told me we can't wait for your tow truck driver to get here, it's to dangerous, so they called another towing company. Well after a long hassle and the 1st tow of $150.00, I got my vehicle towed to my house. After making several phone calls I finally got it towed to the repair shop on 7/8/13 and had to pay another tow of $75.00. Finally got the call on 7/10/13 what had happened to my rotted out expedition, all 4 control arms where rusted out, 2 of them actually bent and broke, damaging my driveshaft. Costing me another $559.14 for the repair. That's only fixing the 2 lower control arms. They have to find the 2 upper and replace them. Which will be at least another $350.00 this isn't even mentioning the $1,000.00 I spent on the rusted out rotted radiator brackets not even a year ago. I was told and expect rust but this is very dangerous, and also told ford could have coated this parts or made them stronger to avoid these serious rust problems. Luckily I only got muscle spasms in my back, shoulder, and lower neck from this. But I don"t feel safe driving this vehicle any more. This is my last ford I will ever purchase again !!!!!!!!!! Ford = found on roadside dead !!! This story is also shortened but the truth of what happened, I didn't mention the heat, the asthma attack I had, and the hassle I went through while all this occurred.

Filed Jul 6, 2013 · Brakes, Suspension · 110,000 miles · PA

Ford expedition 5.4l 2001 - sudden brake failure while traveling 25 MPH in parking lot. Brake lines rusted through caused sudden brake failure. Car had undercarriage cleaning frequently during winter months and there was no indication of any problems. When replacing the brake lines, owner was informed that the upper and lower rear control arms were rusted through as well and that immediate replacement was necessary to avoid the rear track arm failure which results in dropping the rear axle and complete loss of vehicle control. Vehicle was purchased new in june 2001 and maintained continuously.owner has possession of corroded control arms after repair for evidence in the federal safety agency investigation. The federal safety agency is encouraged to contact the owner of vehicle for inspection of failed parts for investigative support.. This is a manufacturers defect and vehicles need to be recalled and parts replaced to avoid loss of vehicle control, accidents, injury and fatalities due to ford motor company negligence.

Filed Jan 17, 2013 · Suspension, Transmission · 150,000 miles · CT

Vehicle is a 2001 ford expedition xlt 4x4 purchased new in april 2001 and owned continuously by current owner, only serviced at hub ford of colchester, ct and girard ford of norwich ct. Failure of suspension/drivetrain components occurred while accelerating onto a highway onramp. Both rear lower control arms had corrosion that LED to complete disconnection from rear axle. With no supporting lower control arms, the rear transaxle shifted during vehicle acceleration. Shifting of transaxle then introduced excessive force on drive shave ujoint (rear transaxle ujoint) which caused complete failure and disconnection of rear driveshaft. Vehicle's 4wd system engaged, allowing vehicle to be safely guided onto the available offramp (cloverleaf highway intersection) and into safe recovery location for towing by aaa to a local ford dealer. Girard ford repair estimates costs for all four corroded control arms to be approximately $1500. Shattered parts or debris also cut rear brake line leading to loss of rear braking and all brake fluid loss - causing additional indirect repair costs. Owner is recovering corroded control arms after repair for evidence to be used in any the federal safety agency investigation. The federal safety agency is encouraged to contact the owner/complainant of vehicle for access to failed parts for investigation support.

Filed Jul 25, 2011 · Electrical · 97,000 miles · MI

Bought a 2001 expedition from a used car lot. Since purchase, cruise has not worked, short in ignition switch which radio and blower stay on and kill battery. Replace tie rod ends, front brakes and rotors, rear seal leaking. Replace ignition switch. Nice looking vehicle but many electrical problems for my wife and kids to be riding in. I have only owned vehicle for 1.5 months and already have spent $1500 in repairs and still has issues. Please help in getting the vehicle in safe running order for my family. This is my wife's car and I seem to be driving it more so they can use my company car for safety.

Filed Jul 6, 2005 · Tires · MA

My 2001 ford expedition's (65300 miles) cable which mounts the spare tire under the vehicle has frayed and the tire has fallen off. I called my local dealership, which just worked on the car, and they said, "ya, we've seen that happen a few times... The cable rusts out, and the tire falls off." I have never bottomed out the car, we have been the sole owners, and it was just in to ford for repairs, and a "safety inspection" so it must have happened recently. I have no idea when or where this could have happened. I must have been driving, because otherwise I would have backed over it, had I been parked. I may have been going 65 MPH down the highway with my three children in the car! And god help anyone behind me! This seems to me to be an extremely dangerous defect, I can only hope my car was not the cause of an accident to another. Now I am forced to endure yet another costly repair to a car, which for its limited 65,000 miles has already had its share. Two months ago I was told that I was lucky that I brought it in for repairs to an engine problem, because its ball joints were so bad that the front wheels were going to fall off! This is not the kind of thing that a mother, who uses this vehicle to transport her three small children around in, wants to hear! And now, the spare tire has fallen off! It will require the replacement of the mounting mechanism, as well as the tire and wheel, assureably, not to be cheap! Thank you for your time and consideration. Respectfully, kim wyman

Filed Sep 7, 2004 · Steering · 68,560 miles · WI

The consumer received an inspection letter from the manufacturer to have the tie rods inspected. The consumer later contacted the manufacturer and asked why? Since the vehicle only has 68,000 miles on it and why should the tie rods be suspect to failure at only 68,000 miles. The manufacturer failed to comment. The consumer is now terrified in fear that the vehicle may have problems that could effect the children. Provide further details.

Filed May 15, 2004 · Steering, Transmission · 55,583 miles · NY

Lower ball joint failure ,no warning. Lower ball joit ,right side-right front axle(inner and outer c/v joints. Replaced ball joit and axle at own expense. Ford said ball joints should last 100,000 miles , vehicle only has 55,600 miles.