As I was driving the transfer case and drive shaft dropped out of truck. Broken bolts and no warning.
Suspension
Ford Excursion Suspension problems by year
40 complaints filed with NHTSA about the Ford Excursion's suspension. Broken springs, struts, control arms, ball joints, noises and alignment that won't hold.
Suspension complaints by model year
Latest Excursion suspension complaints
The contact owns a 2003 Ford Excursion. The contact stated while driving at various speeds, the suspension made an abnormal popping sound. There was no warning light illuminated. The contact stated that an air bubble had formed on the front passenger's side tire which he linked to the suspension failure. The tire was not replaced. The contact also stated that after he replaced the radio inside the vehicle, the radio had become defective after the second day of installation. The contact stated that an abnormal...
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buzzing sound was coming from the speakers. Upon investigation, he linked the failure to NHTSA Campaign Number: 04V327000 (Electrical System). Additionally, the contact also mentioned that the vehicle would stall while at a complete stop without warning. The contact had a friend inspect the vehicle and he informed him that the camshaft needed to be replaced. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 07V553000 (Engine and Engine Cooling). A dealer was notified of the failure and informed the contact that the VIN was not included. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 110,000.
The 2003 ford excursion 6.0 Liter diesel, first broke down while driving home from the dealer who was working on recall items. The vehicle stalled while driving less than 2 miles from the dealer (dealer now out of business). After a while the vehicle began losing power, but not stalling while driving, especially up hills. After many attempts to clean parts, egr valve etc, it was stated that the injectors were bad. All injectors replaced. Front main leaf spring broke on the vehicle, and had to be replaced - the...
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spring was no longer available, -the repair facility stated that this vehicle has been historically undersized, and they stopped making the original spring, because too many were breaking. We then again started experiencing a loss of power while driving - at this time my kids were driving the car, and this was particularly worrisome. My repair shop sent the vehicle to a heavy truck and diesel repair shop, specializing in ambulances. After charging me $3000 to fix my problems (various pieces an part related to the engine, fuel system, etc), the vehicle seemed to operate well. While up in cleveland for thanksgiving, the vehicle lost power on the highway - . Had to have it towed to a dealer, and rent a replacement during our vacation. The dealer said more of the fuel/engine issues and after charging me another $1500, I was able to drive home. Less than one month later, same stalling issues. The vehicle would simply stall, at low speed, high speed, under load, or no load - towed again to my repair person, and he sent it to a different diesel mechanic who told me that diesel is leaking into the engine, the injectors again need to be replaced, that it has never been fixed properly, and that this engine is notorious for having very significant problem. I am out of a vehicle, down to one for the family, and unable to afford getting it fixed - again. *Tr
Tl*the contact owns a 2004 ford excursion. The contact stated the steering wheel felt loose while driving approximately 25 mph. The failure began to recur while driving at various speeds. The vehicle was taken to an auto shop where the contact was told that there was a crack on the front passenger side stabilizer bracket. Crack was welded and a gusset was applied between the bracket and front axle. The failure and current mileages were 169,000. Updated 05/26/11 *bf the consumer stated the crack was three plus...
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inches long and if not corrected would break off and cause the steering to become very unstable, thus making a side load hard to turn, which could easily cause complete loss of control. Updated 06/06/11
2002 Ford windstar rear axle problem we were driving on 78e and were approximately 30 minutes before allentown. All of a sudden we heard a crack, smelled smoke, and heard metal scraping. The car started fishtailing and my husband virtually had no control of the car as the windstar repeatedly crossed 2 lanes and almost hit the middle barrier and then fishtailed toward the other side. Luckily there were no cars or trucks in front or in back of us and we were at a slight uphill. Finally, my husband was able to...
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gain control of the van and pull over to the small shoulder which was barely big enough to fit the van. We called 911 and aaa. While we waited on the side, we feared that we could get hit in the event that a truck or car swerved to the side. We were shocked to find out that the rear axle was cracked and the rear tires were caved in. My auto dealer gilboy in whitehall offered to tow and repair the problem, but only at my expense. Ford explained to me that there was no coverage for this situation because the vehicle is outside of warranty and there currently is no recall for this problem. Both gilboy and ford told me they were not aware of this problem with the rear axle. I had 3 children in the car, 2 of which were my own. This was the scariest moment of my life as I feared what potentially could happen. Luckily, someone from above was looking after us but I fear the next ford windstar owner may not be so lucky. Please do not wait for someone to get killed before taking action. Please have the problem corrected as soon as possible and alert all ford windstar owner of the serious potential risk. *Tr
We purchased 2004 ford excursion with the 6.0L diesel engine new in february 2004. It has been to the dealer now 2 times for the back up sensor, approximately 5 times for the turbo, unable to count the number of times for the lack of power, the vent windows not working, 3 times for the motor on the power drivers seat, ball joints 1 time, and now other front end parts. This vehicle is primarily used to go to church and travel with the entire family on the weekends for day trips. We have had it to graham ford several...
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times, germain ford several times, (both are in columbus, ohio) and the last place we have it is donley ford in mount vernon, ohio. We can get a full history of all repairs on this vehicle if needed. There have been so many things gone wrong with the truck that it is difficult to keep track. The service advisor is now telling my wife to "just trade it in". We just want all of the problems fixed correctly and find the cause of the electrical failures/issues/problems instead of just fixing what breaks and not fixing the cause. We paid 50,000 bucks for this vehicle and have had nothing but problems. The start was when we wanted to go to maine and could not take it but had to take our older conversion van. *Tr
While driving my 2002 ford taurus I experienced the failure of both front coil springs which cut open like a can opener one front tires and damaged the other. I had to have both tires and springs replaced. If I was traveling more than 15 mph I fear I would not be here today.*Cn
All four wheels bearings on a 2002 ford explorer with only 70,000 miles had to be replaced. One incident included a wheel falling off due to the failure of these bearings. *Tr
Tl*the contact owns a 2003 ford excursion. The contact took the vehicle to the dealer due to a rattling noise in the front end. The failure was noticed while driving 10 mph. He was informed that all four ball joints needed to be replaced. Seventeen thousand miles after the replacement, he took the vehicle to be inspected and it failed because of the ball joints. The contact returned to the dealer and they confirmed that all four ball joints should be replaced again. The failure mileage was 78,500 and current mileage was 95,500. Updated 03-04-08 *bf
I am an owner of a 2002 ford explorer 2wd. At the beginning of october the vehicle starting making a horrible noise. The loud noise was coming from the rear passenger wheel. Come to find out, this is a major wheel bearing issue. I have recently gotten online and discovered how many other people are also having the same issue. What can we do to get the ford company to be held responsible for this very dangerous defect in their product that you are supposed to trust not only your life but the lives of all your...
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passengers. How can companies continue to sell their unsafe vehicles to the public. It is enough to have to worry about getting my 1 year old to and from her nana's without having to worry about getting hit by someone, but to worry that any moment your vehicle can cause a major accident without you even being at fault because of faulty parts. Please, can someone with any kind of decency do something to get this company to recall every vehicle with faulty parts. Common sense would say it's the right thing to do. *Tr
Front strut spring broke for no apparent reason. *Tr
Both rear coil springs defective parts. Ford was willing to help me with this cost of the repair. *Ak
Rear coil spring on 2002 ford taurus broke and damaged the left rear tire. I researched online and found numerous complaints. This could have been a major accident.
I was turning on to my street when I heard avery loud bang and my car stopped immediately. As I sat there in shock it appeared that my car was tilted down on the left side. I got out of my car and sure enough it was leaning. The body of my car was resting on the top of the tire. Since I couldn't drive it I called a tow truck and had it towed to a garage to be looked at. After my car was inspected for the reason for the bang I was told that the front coil spring was broken in two places. Also, the sway bar was...
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broken and the front strut mount and bearing were broken. What could I do but have the repairs made. I had two new front coil springs put on (i wasn't taking any chances with the other spring), a new sway bar, a new strut mount and bearing put on at a cost of $444.64. I had just come off of the highway where the speed limit is 65 mph. If the spring would have broken there, I shudder to think what the outcome would have been. I still have the broken spring. It still has the protective coating on it. So corrosion could not have been a factor. *Nm
Purchased a used 2002 explorer in 12/2005. In 2/2007, a grinding noise appeared when I would accelerate. Took it in the same day (i was on the expressway when it occurred). They told me the bearing was bad and that I needed about $1100 in parts and $600 in labor to replace, and that I was lucky that the wheel did not fall off. He stated that, "this is common on mountaineers and explorers," and that he has done similar work other times. He recommended that I replace the other bearings, because they were all going to go at some time. I feel there should have been a recall on this issue. *Jb
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked daily. Complaints are owners' own reports and are not verified. How we use the data