2002 MERCURY MOUNTAINEER Complaints

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.*AK

FORD HAS BOUGHT BACK CAR - HOPEFULLY, TOMORROW WILL BE THE TRANSITION DAY. FOR THE TRANSMISSION, CAR HAD BEEN IN 3X - TRANSMISSION KICKED AT VARIOUS SPEEDS. STARTING IN 12/01, 4X (INCLUDING ONCE IN THE DEALERSHIP), THE CAR WOULD NOT START. FEEL THAT THIS IS A MAJOR PROBLEM W/ CAR. RECEIVNG NEW CAR, BUT I THOUGHT THIS INFO. SHOULD BE PART OF NHTSA FILE.*AK

UPON PURCHASE, A RAW GAS ODOR WAS NOTICEABLE--RETURNED TO DEALER--NO PROBLEM FOUND; RETURNED AT 4000 MILES WITH SAME PROBLEM--REPLACED FUEL INJECTOR; THIRD TIME MAJOR FUEL LEAK FROM RIGHT SIDE FUEL RAIL AT UPPER SEAL ON CYL 3 & 4 O-RING REPLACED--DEALER HAD US CALL TOW SERVICE AND THE DEALER TOOK CARE OF REPAIRS UNDER WARRANTY--GREAT CONCERN ABOUT SAFETY DUE TO POSSIBLE OF A SERIOUS FIRE FROM FUEL LEAKAGE ONTO HOT ENGINE. *AK

CONSUMER WAS TRAVELING ON A ROAD LESS THAN 20MPH AND APPLIED BRAKES, AND VEHICLE KEPT ON GOING. VEHICLE STOPPED WHEN SHE WAS AT BOTTOM OF HILL. THERE WERE NO WARNING SIGNALS. THIS INCIDENT HAPPENED TWICE. DEALERSHIP WAS AWARE OF PROBLEM. *AK

CUSTOMER HAS CONCERN ABOUT SAFETY OF VEHICLE BECAUSE OF A THRID PARTY DEALER MODIFYING AND INSTALLING A MOON ROOF IN THE INTERIOR HEADLINER OF VEHICLE, ALTHOUGH OWNERS MANUAL WARNS AGAINST ANY MODIFICATIONS OF HEADLINER WHEN VEHICLE HAS SIDE AIR BARS INSTALLED. *JG

WARNING IN OWNERS MANUAL STATED DO NOT MODIFY HEADLINER ON VEHICLE WITH SIDE AIR BAGS, ALSO DEALER PUT SUNROOF IN VEHICLE FROM WHICH HEADLINER HAD TO BE TAKEN OUT, THIS VEHICLE WAS MODIFIED WITH NO REGARD FOR WARNING IN OWNERS MANUAL. CONTACTED DEALER, AND NO RESPONSE FROM DEALER OR FORD CUSTOMER SERVICE.*AK *SLC

THREE SETS OF GOODYEAR, EAGLE LS TIRES, SIZE P24570R16 (NO DOT # MENTIONED) WITH LESS THAN ONE HUNDRED MILES HAD TO BE REPLACED BECAUSE KNOTS WERE FOUND ON SIDEWALL AND TREAD. DEALER HAS BEEN CONTACTED. *AK ENGINE LIGHT ILLUMINATED DUE TO FAULTY DPFE SENSOR; AIR BAG LIGHT ON, AIR BAG MODULE REPLACED; LOOSE REAR CENTER CONSOLE; VIBRATION AND POPPING NOISE OVER BUMPS, REPLACED AND BALANCED ALL FOUR TIRES, REPLACED STABILIZER BAR LINKS, RIMS WERE OUT OF ROUND; SCRUNCHING NOISE WHILE TURNING, RACK AND PINION REPLACED; EXPERIENCING WHISTLING NOISE; HARD JERK AND POPPING NOISE WHEN SHIFTING, GEAR SELECTOR SLIPPAGE; A/C VENT SQUEAKING, A/C VENT READJUSTED. *TT

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 *TT

A VIOLENT JERK IS PRESENT WHEH SHIFTING OUT OF PARK. A NOISE CAN BE HEARD ON AN INTERMITTENT BASIS BEFORE JERK OCCURS. DEALER HAS BEEN CONTACTED. *AK *TT

WHILE GOING UP A HILL AT 30 MPH CONSUMER NOTICED DASH LIGHTS FLICKERING ON AND OFF. A WHILE LATER ENGINE SHUT DOWN, VEHICLE HAD TO BE TOWED TO DEALER. ON NOVEMBER 1ST, WHILE TRAVELING AT ABOUT 60 MPH, ENGINE DIED. CONSUMER TRIED TO RESTART WHILE CAR WAS COASTING TO AVOID A REAR END COLLISION, LUCKILY VEHICLE RESTARTED. CONSUMER FELT VERY LUCKY. PLEASE PROVIDE ANY FURTHER INFORAMTION.*AK