Problems with 2004 Ford Expedition STRUCTURE

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?

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

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.

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). *tr

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.

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.

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. *tr

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. *tr

Tl* the contact owns a 2004 ford expedition. while driving in rainy weather conditions approximately 30 mph, the interior dome light began leaking a small amount of water. the vehicle was taken to an authorized dealer and they recommended the vehicle be taken to an auto collision center for inspection. the vehicle was taken to an auto collision center and the technician stated the roof of the vehicle would need to be replaced and also informed the contact that eventually, the water leakage would result in electrical issues. the manufacturer was made aware of the problem. the approximate failure mileage was 67,000.

Bubbling paint on rear tail gate. clearly a paint preparation issue, otherwise paint on the rest of the car is near perfect. *tr

Tl* the contact owns a 2004 ford expedition. while driving water began pouring from the roof console . water entrance has caused corrosion and holes on the roof-top. the dealer was contacted and they stated that the vehicle was designed defectively. since the warranty expired and the failure occurred previously, they agreed to pay for half of the repair. meanwhile the technician gave her a black caulk to fill in the holes. the temporary repair was not a remedy. the failure mileage was unknown. the current mileage was 48000.

Tl*the contact owns a 2004 ford expedition. the contact turned the engine off and exited the vehicle. suddenly, a fan blowing noise came from underneath the hood area and the interior lights blinked continuously. the engine was restarted and turned off. however, the failure continued to occur. when the battery cable was disconnected the failures stopped. the failures occurred under rainy conditions on several separate occasions. the vehicle was taken to an authorized dealer for inspection. the technician stated the failure was contributed to water leaking into the smart junction box apart of the electrical system. the contact scheduled an appointment for diagnostic testing. the vehicle had not been repaired at the time of the complaint. the failure mileage was unknown. updated 7/16/10 *cn the consumer stated the failure has been corrected, even though she had to pay out of pocket. updated 07/22/10*jb

1 own a 2004 ford expedition and the original paint is bubbling up on the tailgate around the license plate holder and door handle there have been hundreds of complaints and ford does not want to except responsibility. *tr

Tl* the contact owns a 2004 ford expedition. the contact stated that there was corrosion on the rear liftgate. the vehicle was taken to the dealer who stated there were no recalls for the failure. the manufacturer was also contacted who confirmed that there were no recalls and offered no further assistance. the vehicle was not repaired. the failure mileage was 97,000.

Tl* the contact owns a 2004 ford expedition. the paint near the front hood, the rear lift gate, the door latch and the wind-shield wiper has corroded. the vehicle has not been inspected or repaired for the failure. the failure mileage was 90,000. the current mileage was 93,000. updated 11/12/09 *cn the consumer stated the vehicle has never been in an accident. the vehicle is stored in a garage overnight. updated 11/17/09.*jb

Tl*the contact owns a 2004 ford expedition. the contact stated that there was inadequate sealant on the front windshield. in rainy conditions, water would leak into the vehicle. in addition, when the windshield wiper unit was activated, the windshield cleaner would also leak into the vehicle. the contact could hear a crackling sound coming from the dashboard. all the digital components on the instrument panel became inoperable due to the leak in the front windshield. the dealer stated that the windshield could be resealed at the cost of less than $100. if the windshield needed to be replaced, it would cost over $200. there were no recalls for the failure. on a separate occasion, the engine started on its own. the vin was unable to be accepted by the system. the current and failure mileages were less than 97,000. updated 04-20-09 *bf updated 04/24/09.*jb

Black plastic trim molding on doors of 2004 ford expedition are fading. all of them on the road of this vintage have the same defect. *jb

Roof canel rust, had repaired it 4 times since 2007. ford is unwilling to take ownership of the defect and with each repair, the roof is weaker. spoke to two dealerships and this defect keeps them in business since this is all they do. *tr

Paint peeling,creating corrotion on the roof. *tr

My letter to paoli ford to: paoli ford 3/18/06 attn. general manager re: 2004 e.b. expedition purchased 3/04 problems: door rattles, brake failure no ford product to date has required as many service calls as this 2004 expedition. the door rattles have never been totally fixed after7 attempts. i believe that there is a design flaw in the advance trac system that has caused a brake failure on two occasions. i do not intent to wait around for a third time. last summer, i was traveling at approximately 50 m.p.h. when approaching a light in heavy traffic. the brakes failed. the pedal pulsated as if i was on ice, but the pavement was perfectly dry. i avoided a massive rear end collision by taking evasive action, and driving over a berm. the brakes acted as if they had about 10 % of their stopping power. when i called the service department at paoli ford, they suggested i restart the vehicle and turn off the advanced trac button. this did restore the brakes. i dropped the truck off and they replaced some yaw sensor parts under warranty, and declared it safe to drive. this same brake failure has now happened again! the message center indicated 2 advtrac faults, but the service department says that the fault codes scrolled off the system by the time they were able to test it. they suggested that i drive it until the brakes fail again. i will not subject my family to the danger of this situation again! i do not ...

Tl*the contact owns a 2004 ford expedition. the contact stated that the radio light has been illuminating intermittently for the past year. currently, it has turned completely off and the odometer light illuminates intermittently every other day. the contact stated that during the entire winter season, when she would close the two passenger doors, they would pop back open. since the weather has warmed up, the doors are closing and staying closed more often. she also stated that the check engine light illuminates and was told that this was due to the fuel injection. the vin and engine size were unknown. the current mileage is 113,000 and failure mileage was 70,000.

The 2004 ford expedition is built too low to safely take off road. because of its lack of clearance ford installed skid plates to protect the exhaust manifold, catalytic converter, etc. the skid plates collect leaf litter which accumulates right next to very hot components. this is a fire hazard. it is difficult to keep the skid plates litter free because of the many angles and tight spaces. the litter does not blow out once back on the highway. after a day of driving off road, i noticed tar-like material from smoldering leaf litter dripping from the skid plates. i had tried several times during the day to knock the litter out but it did no good. it should not be necessary for a driver to put their face under a vehicle near very hot components, on a daily basis, in order to maintain a safe vehicle. *la