2002 Mercury Mountaineer: ball joint or control arm failure

Filed Feb 16, 2010 · Suspension · 121,000 miles · MA

Tl* the contact owns a 2002 mercury mountaineer. The contact was driving approximately 40 MPH on normal road conditions. There was a loud noise outside of the vehicle. The driver pulled over to the side of the road and inspected the vehicle. The vehicle resumed operation with caution to the residence. The vehicle was towed to an independent mechanic. The failure was contributed to the front and rear control arm. The front and rear control arms were replaced. The failure mileage was 121,000. The VIN was unavailable.

Filed Dec 1, 2008 · Suspension, Tires · 34,200 miles · MO

Tl*the contact owns a 2002 mercury mountaineer. The vehicle has toyo open country at tires, size p22570r15 (na). The tires were purchased brand new in may of 2007 from jensen tire company while driving 15 MPH. At 36,000 miles, the rear passenger tire blew out in june of 2008. The repair shop stated that the tire was worn down to the steel. The tire company from where the tire was purchased is providing reimbursement for the failed tire. The remaining tires were inspected by other shops and each shop recommended that the rest of the tires be replaced. Toyo stated that the tires needed an alignment. The contact stated that an alignment had just been performed; however, the manufacturer advised her to have another one. While the vehicle was at the shop, the mechanic stated that the ball joints were defective due to the damage caused by the tires and needed to be replaced. The ball joints have not been replaced and the manufacturer is refusing responsibility for the repairs. The failure mileage was 34,200 and current mileage was 123,402.

Filed May 11, 2007 · Transmission · 72,000 miles · MT · crash · 10 injuries

Tl*the contact owns a 2002 mercury mountaineer. While driving 35mph and losing control, the vehicle was in a ditch on a dirt road. The tie rod broke and two front tires had to be replaced and the truck is damaged. The contact has paid over $6000.00 in repairs since purchasing the vehicle. The contact had to repair the front differential, lower ball joints, sealing for both shafts, four brake pads, bearings on all four tires, and the rear transfer case was flushed twice. Ford stated that the vehicle can be repaired. The contact is aware of the safety risk involved and request that the dealer purchase the vehicle from her. The failure mileage was 72,000 and the current mileage was 102,000.

Filed Oct 28, 2006 · Suspension, Transmission · 88,345 miles · MT

Bought used from a dealer 10-05 with 71328 miles. Checked out by mechanic. No problems w/ drive train, tranny, or suspension, except to change fluids in differentials (rear & front). Did this first week we owned it & water found in rear differential. 1st owner's records came with car. All services were done (no mention of problems). I serviced it every 2-3000 miles. On 4-27-06 the tranny flushed, & the rear differential & transfer case serviced. Mileage was 85857. 2 new tires put on front on 5-25-06 (flat tire). On way home (18 mi. Into 35 mi. Drive), front end started to fail. Couldn't find source of leaking fluid. Drive home. Next morning, tried to return to mechanic with car. Made it about 25 of the 35 miles to town before front end failed. Mechanic showed us the gears from the differential--the "teeth" were sheared completely off 1/3 of it--remaining teeth sheared down by at least 50%. Front differential was replaced, also 4 ball joints, seals for both shafts, brake pads (from differential fluid damage) were replaced. All 4 wheels had bearings repacked. 2 more tires bought. Within 1 week, began hearing noise again from drive train. Car back at mechanic on 6-20-06. The noise now from rear transfer case. It was flushed 2 times (fluid filled with fine metal fragments). The rear differential fluid also changed. Mechanic said 4-6 months until rear end failed. I've now lost the rear end--also have to replace all 4 sets of wheel bearings & replace all axles. Will re-assess front differential after rear is fixed. We've contacted ford, no recalls for our car. They'll not make any repairs or reimburse for faulty equipment. I'm not original owner & warranty has expired. It doesn't qualify for state lemon law (mileage). There's at least 31 problems and 18 complaints on your website that I've had in the 1 year since I bought this car. This is a ford issue. I just want to re-coup my $4000+ in repair costs & trade it off for a non-ford SUV.

Filed Feb 27, 2002 · Steering · MI · crash

My son was making a turn in boulder when the car slid into the curbing. This was on a icy road and the car was traveling at less than 5 MPH. After stricking the curbing, the car would not track so he took it to the dealer for evaluation. It was identified that the rear tie rod end had broken off and that a new assembly must be installed. My son called me and I requested the part be sent to my attention. I am an automotive engineer and I know that this is not an normal failure mode for this part. I also need to point out that there were no marks on the tire and that the wheel was not damaged in the event. Upon receipt of the failed part it became very apparent that a manufacturing problem exists. The tie rod is threaded on the rod and then swedged to hold it in place. In order to swedge the part the wall thickness has been reduced to less that 1/8" and in the swedging process, the material is streched over the shoulder between the solid mass of the tie rod and the drilled out (reduced wall thickness)section of the tie rod that is then threaded and swedged in-place. The part also has rust present on the inside of the break which is an indication that a crack was present that was most likely created by the high mechanical stresses in the swedging process. I am concerned that this problem is present on all the new 2002 ford explorers/mountaineers. This is a new suspension system for 2002. A large bump in the road at any speed above 30 MPH could be catastrophic! I have not made contact with ford and still have the part in my possession. Please advise what the next steps should be.

Filed Nov 27, 2001 · Suspension · LA

A loud popping noise could be heard coming from front end of vehicle. Dealer has been contacted for problem, and replaced tie rods. Consumer stated that this did not remedy the problem. *ak