2004 Ford Expedition body problems

Filed Nov 21, 2022 · Body, Steering · 110,665 miles · NY

The contact owns a 2004 Ford Expedition. The contact stated while driving approximately 10 MPH, the vehicle lunged forward while depressing the accelerator pedal. The contact was unable to drive above 15 MPH because the vehicle became difficult to control. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the rear axle was fractured, the rear subframe was severely corroded, and the rear driver's side sway bar and rear differential were corroded. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was 110,665.

Filed Aug 5, 2020 · Body · 85,000 miles · PA

The frame is rusting. See photos. The body is rusting away also the brake lines. The entire vehicle is rusting away. Why has this 2004 ford not included in a recall for rust.

Filed Jun 28, 2019 · Body · PA

Frame was broken and rigged and painted unsafe and I am concerned when he puts my kids in the car it is not safe

Filed Sep 24, 2018 · Body, Suspension · 125,000 miles · PA

Rusted out rocker panels, brake lines, front end radiator mounts, fender mounts. The entire under carriage is rusting away. We have had to replace all the brake lines as they have rusted away, redid the rocker panels rust away. Now we have to replace the entire front end because of rust. Will not pass pa state inspection due to rust. Is the expedition in the recall for rust?

Filed Feb 12, 2016 · Body · 66,000 miles · NY

Tl* the contact owns a 2004 ford expedition. The contact stated that while driving at various speeds, there was an abnormal noise coming from the vehicle. The vehicle was taken to the dealer where it was diagnosed that the passenger side rear frame rail section had rusted through and separated. The dealer also diagnosed that the wheel bearing and hub assembly needed to be replaced as well. The contact stated that the dealer stated that the vehicle was no longer road worthy due to rust of the frame and should not be driven. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 66,000.

Filed Feb 1, 2015 · Body · PA

Paint failure ref. Tsb# 06-25-15 [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Apr 22, 2014 · Body · 180,000 miles · WI

Tl* the contact owns a 2004 ford expedition. The contact stated that upon inspection, it was found that the sub frame was rusted. The contact also indicated that the radiator mounts detached from the vehicle. The vehicle was taken to an independent mechanic who confirmed the failure. The manufacturer was notified. The VIN was not available. The failure mileage was 180,000.

Filed Oct 17, 2013 · Body, Brakes · MS

Was driving when brakes went completely out when I went to stop at a stop sign. . Cause due to rust corrosion . Brakes giving out could have caused a fatal car accident . Rust has damaged all brake lines and fuel lines . Rust is now moving up the vehicle. Brake lines and fuel lines should have a protected coating or made with a non corrosion metal. I had no idea that my brake line was rusted out till my brakes gave out. These vehicle need to be recalled and have new lines. Also have a protected coating applied under the vehicle to stop rust. Very very dangerous driving around not knowing that you have rust under your vehicle eating away at your brake lines and fuel lines.

Filed Aug 30, 2013 · Body, Suspension · 103,000 miles · NJ

My truck has started making a very loud noise coming from the front under side of the vehicle. Upon further investigation we have discovered that there was excessive rust and corrosion on the frame. This has caused parts of the engine to shift and rub/ collide with other parts and cause the noises. Our mechanic and my husband both feel that the rust and corrosion have made the vehicle unsafe to drive. There is no way to tell when any part of the engine/vehicle could break free, possibly causing more damage and or an accident while driving. Our vehicle is very well maintained and the amount of rust and corrosion is excessive for the year and mileage on the vehicle. The lack of ability to tell when or where the framework may give out makes it unsafe in our opinion to drive. Especially with children in the vehicle most of the time. The corrosion is also so excessive we believe it is not repairable by any body shop. My frustration with this is that we had not planned on getting a new vehicle and were planning on driving it for quite awhile longer. Other then the rust and corrosion the vehicle is in fairly good condition.. I believe that the rust and corrosion sounds very similar to that described on the windstars and should be investigated along with the windstars problems. Finally there is also excessive bubbling of the paint in various locations of the vehicle.

Filed Oct 17, 2012 · Body · 107,000 miles · NJ

Observed significant rust-through and deterioration of the body structure at the two front body to frame mounting points. Metal structure supporting the air conditioning condenser coil has completely disintegrated and the coil has dropped approximately 1" from its designed position. Metal structure supporting the radiator is almost completely disintegrated. Surrounding metal supporting the body to frame sown significant deterioration and rust-through. Concerned with safety and structural integrity of the body to frame connection and support of components.