2002 Ford Expedition: ball joint or control arm failure

Filed Feb 23, 2014 · Body, Suspension · 85,000 miles · PA

During inspection it was noticed that the upper and lower rear control arms were rusted through and unsafe. Had them replaced including the rusted through shocks. Hood and roof paint shows serious paint peeling and bubbling.

Filed Sep 19, 2013 · Brakes · 117,000 miles · MD

Brake line ruptured in rear of vehicle when pulling into service station hauling my travel trailer. Was told the line was completely rusted through and this is a common problem on these model year vehicles. I find totally crazy to find brake lines rusting on a vehicle of this age. I was also told the rear control arms need to be replaced because of the rust. I know this was an issue on the windstars and it was recalled ford need to take care of this. Thank god it happened at the station and not hauling my kids to the campground. This needs to be addressed due to the fact there are thousands of these vehicles still on the roads.I know if I call ford they will tell me its not in warranty that's why I contacted you. They cover airbags and seatbelts for life they should cover brake lines.

Filed Oct 18, 2007 · Suspension · 89,002 miles · MA · crash · 1 injury

Tl*the contact owns a 2002 ford expedition. The contact took his vehicle to the dealer for a routine service check and they replaced the lower driver side ball joints. A few weeks later, while driving approximately 25 MPH, his vehicle was struck on the front passenger side by another vehicle. The contact suffered minor injuries. He drove his vehicle home and noticed a burning smell. The following day, the vehicle was towed to a local dealer. The dealer stated that both the upper and lower ball joints needed to be replaced, even though they were just replaced 500 miles ago. The contact also noticed that whoever replaced the ball joints did not check his alignment. The vehicle is currently still at the auto shop and has yet to be completely repaired. The current mileage was 89,500 and failure mileage was 89,002.

Filed Sep 27, 2006 · Steering, Suspension · 110,000 miles · MI

Dt*: the contact stated while driving on a paved interstate, the passenger side front tie rod fell off. An independent mechanic determined both sway bars were fractured and the other three tie rods needed to be replaced. There were no problems with the vehicle prior to the incident. The dealership was aware of the problem. Updated 11/3/2006 -

Filed Jul 3, 2006 · Suspension · 66,663 miles · VA

Failure of rear air suspension while driving. Found previous modification to rear height sensor, replaced ball joint brackets with bolt, washer, and nut. "dealer not responsible", but they did adjust the sensor prior to sale.