2002 Ford F-150 Suspension Problems

I WAS DRIVING MY 2002 FORD F-150 VIN # ([XXX]) DOWN THE HIGHWAY AT 45MPH WHEN IT STARTED WHEEL HOPPING FROM THE REAR VERY BAD, THERE WAS A SCHOOL BUS STOPPED LETTING CHILDREN OFF & AS I WAS BRAKING IT WAS HOPPING & WAS A NEAR MISS, THIS WAS CLOSE. I PULLED THE TRUCK OFF THE SIDE OF THE ROAD TO INSPECT AS I AM MECHANICALLY INCLINED & RETIRED, FOR THE FIRST 10 YEARS OF MY LIFE I WORKED IN THE AUTOMOBILE FIELD BECAUSE I HAD SCHOOLING FOR IT, ANYWAY I LOOKED UNDER THE TRUCK & SPOTTED THE PROBLEM RIGHT OFF THE BAT, BOTH REAR CENTER LEAF SPRINGS ARE BROKEN BIGGER THAN CRAP. I AM 54 AND A DIE HARD FORD FAN AND HAVE BEEN SINCE THE AGE OF 16, THAT IS ALL I HAVE OWNED & I AM THINKING ABOUT SWITCHING BRANDS BECAUSE THIS IS NOT THE FIRST TIME I HAVE BEEN DISAPPOINTED WITH THIS TRUCK. I AM THE SECOND OWNER, I BOUGHT IT IN 10/2004 WITH 13,000 MILES. IT HAS NEVER HAD ANYTHING OVER 100 POUNDS HAULED IN IT AND I AM THE ONLY ONE WHO HAS DRIVEN IT SINCE I BOUGHT IT. IS THERE ANY RECALLS FOR MY TRUCK ON THIS PROBLEM? CAN FORD MOTOR COMPANY DO ANYTHING FOR ME? THANK YOU [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

THE REAR PORTION OF THE FRAME IS ROTTEN TO THE POINT THAT THE LET SPRINGS HANGERS ARE READY TO BREAK OFF THE FRAME AND THE SPARE TIRE HOLDER IS ALSO READY TO FALL OFF. I JUST REPLACED THE REAR SPRING SHACKLES DUE TO THE WERE ALSO ROTTEN AND BROKE. THE GAS TANK STRAPS WERE ALSO A PROBLEM DUE TO RUST BUT FORD THOUGH ENOUGH OF THE PROBLEM THERE WAS A RECALL ON THAT, TOYOTA HAD A PROBLEM WITH RUSTED FRAMES AND DID A MASSIVE RECALL ON THAT ISSUE. WHY HASN'T FORD DONE THE SAME THING? THE FRAME SHOULD BE THE LAST THING ONE NEEDS TO WORRY ABOUT WITH ANY VEHICLE. THE TRUCK CURRENTLY HAS 146000 MILES AND NOW WE NEED TO FIGURE OUT WHAT THE NEXT MOVE WILL BE WITH THIS VEHICLE. REPAIR IT, JUNK IT OR TRADE IT ????? *TR

LEAF SPRING BRACKETS ATTACHED TO THE FRAME HAVE RUSTED OUT AND HAVE SEPARATED THE LEAF SPRINGS FROM THE FRAME. *TR

MY TRUCK THAT I BOUGHT BRAND NEW IS A 2002 FORD F150 SUPERCREW THAT I TAKE VERY GOOD CARE OF. THE TRUCK HAS JUST OVER 64,000 MILES ON IT. ON OCCASION I DO USE THE TRUCK LIKE A TRUCK AND TOW A 19' BOAT WITH IT AND I USE IT TO PICK UP LUMBER ETC... THREE WEEKS AGO I BEGAN TO HEAR AN ODD METALLIC SOUND FROM THE BACK OF THE TRUCK WHILE GOING OVER BUMPS IN THE ROAD. I CLIMBED UNDERNEATH AND GRASPED DIFFERENT COMPONENTS OF THE SUSPENSION AND DRIVE TRAIN AND PUSHED AND PULLED ON THEM EXPECTING TO FIND SOMETHING LOOSE. I DIDN'T FIND ANYTHING. THE NEXT DAY I WAS DRIVING DOWN THE ROAD AND I HEARD A VERY LOUD BOOM! I PULLED OVER AND AGAIN LOOKED AT THE REAR END OF THE TRUCK AND FOUND THAT THE MOUNT THAT HOLDS THE REAR LEAF SPRING TO THE FRAME BODY HAD BROKEN RATHER VIOLENTLY AND SENT THE END OF THE SPRING WITH HALF OF THE MOUNT THRU THE UNDERSIDE OF THE TRUCK BED. I WAS ABLE TO LIMP HOME. I BROUGHT THE TRUCK TO THE LOCAL BODY/ FRAME SHOP AND THE OWNER TOLD ME THAT HE HAS BEEN SEEING ALOT OF THESE LATELY AND IT IS A COMMON PROBLEM. AFTER INSPECTION HE FOUND THE OTHER SIDE WAS EQUALLY RUSTED AND READY TO LET GO, WHICH CONCERNED ME SINCE THAT IS THE SIDE WITH THE GAS TANK ON IT. IN HIS EXPERT OPINION HE BELIEVES THAT FORD HAD UNDERBUILT THE LEAF SPRING MOUNTS AND THAT IS WHY THEY ARE BEGINING TO FAIL ON TRUCKS THAT ARE AROUND THE AGE OF MINE. THE FRAME IS SAFE AND SOLID ENOUGH BUT THE MOUNTS FOR PARTS OF THE SUSPENSION APPEAR NOT TO BE. I AM FORTUNATE THAT I WAS NOT TOWING MY BOAT, OR THAT THE BED WAS NOT LOADED AND I WAS NOT DRIVING MORE THAN 35 MPH WHEN THE MOUNT LET GO. I DON'T KNOW WHAT MIGHT HAVE HAPPENED IF I WAS ON THE HIGHWAY AT 65 MPH. THE REPAIR COST $659 AND IN MY OPINION IT IS SOMETHING THAT SHOULD NOT HAVE FAILED CONSIDERING THE AGE, CONDITION AND THE LOW MILES I HAVE ON THE TRUCK. IF THIS TRULY IS A COMMON PROBLEM THAT FORD F150'S LIKE MINE POSSESS THAN IT IS ONLY MATTER OF TIME BEFORE THE FAILURE OF THESE PARTS CAUSE A BAD ACCIDENT. *TT

BOTH THE REAR SPRING SHACKLES AS WELL AS THE BRAKE LINES HAVE FAILED ON MY 02 FORD F150 DUE TO RUST AND THIS IS A COMMON CONCERN. I AM A SENIOR MASTER TECHNICIAN FOR FORD AND WE REPAIR THESE ON A REGULAR BASIS DUE TO RUST. BOTH ARE CLEAR SAFETY CONCERNS WHEN THEY FAIL AND SHOULD BE ADDRESSED. AND WITH THE FORD WINDSTAR AXLES AND SUBFRAMES BEING COVERED BY A RECALL DUE TO RUST I DO NOT UNDERSTAND WHY OTHER RUST RELATED SAFETY CONCERNS ARE NOT RECALLED. IF ONE RUST RELATED CONCERN IS RECALLED THEN ALL OTHERS SHOULD BE AS WELL, IT SHOULD BE ALL OR NONE. ON THE REAR SPRING SHACKLES, THEY WILL SNAP IN HALF AND THE REAR EYELET OF THE LEAF SPRING JAMS INTO THE BOTTOM OF THE TRUCK BED, WITH THE BED BEING THE ONLY THING KEEPING MAJOR DAMAGE OR AN ACCIDENT FROM HAPPENING. ON THE FRONT BRAKE LINES, THE RUST AND SWELL UP UNDER THE RUBBER PART OF THE LINE WHERE THE LOWER STEEL LINE IS INSERTED INTO THE RUBBER. ON HARD BRAKE APPLICATION THE LINE BLOWS AND YOU LOSE FRONT BRAKES. BOTH ARE COMMON CONCERNS ON TRUCKS IN NEW ENGLAND WHERE RUST IS A PART OF LIFE. IF I WASN'T A TECH THAT DRIVES VEHICLES WITH FAILED BRAKES AND BROKEN SUSPENSIONS ON A REGULAR BASIS, BOTH OF THESE FAILURES COULD HAVE CAUSED A MAJOR ACCIDENT AND LIKELY INJURIES. *TR

I HAVE A 2002 F150 WITH ABOUT 90,000 MILES ON IT. ABOUT THREE MONTHS AGO THE FRONT END STARTED SHAKING VIOLENTLY AT ABOUT 45MPH. IT WILL NOT STOP SHAKING UNTIL YOU PRETTY MUCH COMPLETELY STOP. STARTED OUT JUST DOING IT EVERY NOW AND THEN. NOW I CANT GET OVER 45MPH. THIS IS VERY DANGEROUS. I HAVE TAKEN IT TO 4 DIFFERENT FRONT END SHOPS AND THEY ALL END UP SAYING THE SAME THING. DON'T KNOW WHAT IT IS.. THIS OBVIOUSLY IS A DESIGN FLAW AND SERIOUSLY NEEDS TO BE FIXED. *TR

2002 FORD F-150. CONSUMER STATES PROBLEM WITH REAR AXLE AND BEARING *TGW THE CONSUMER STATED THERE WAS A GRINDING NOISE COMING FROM THE REAR OF THE VEHICLE. THE RIGHT REAR AXLE WAS WORN AND THE BEARING WAS BAD. *JB

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 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

MY DAUGHTER WAS ROUNDING A CORNER IN HER FORD F150 KING RANCH TRUCK MAKE A HARD PULL TO THE RIGHT AND SHE TRIED TO CORRECT IT AT THAT TIME HER TRUCK BEGAN TO FLIP OVER TWICE. SHE ENDED UP IN A 10FT UPSIDE DOWN TOTALED HER TRUCK AND BROKE HER COLLAR BONE. THERE WAS A WRECKER DRIVER ON THE SCENE THAT NOTICE THE REAR AXLE ON THE DRIVERS SIDE OF HER TRUCK HAD BROKE IN HALF AT THE TIRE. SPOKE WITH THE ORIGINAL OWNER AND THEY SAID THERE SON HAD COMPLAINED TO THEM ABOUT A NOISE IN THE REAR END BUT THEY COULDN'T FIND ANYTHING WRONG. *TR

WHILE GOING AROUND A HAIRPIN TURN THE DRIVER SIDE FRONT TIRE FELL OFF ROTOR AND ALL, THIS INCIDENT CAUSED THE 2002 FORD LIGHTNING TRUCK TO SLIDE INTO THE CURB CAUSING THE TRUCK TO ROLL COMPLETELY OVER LANDING BACK ON IT'S 3 TIRES THAT WERE LEFT. FROM THE LOOK OF IT THE AXLE BOLT FELL OFF CAUSING THE TIRE TO FALL OFF. DRIVER WAS GOING UNDER THE SPEED LIMIT & NO OTHER VEHICLES WERE INVOLVED. ACCORDING TO A FRIEND THIS SAME INCIDENT HAPPENED TO HIS LIGHTNING TRUCK. SOUNDS LIKE A DEFECT ON FORDS PART. *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

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 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

75400 MILES. NOISE FROM REAR END BECOMING MORE NOTICEABLE. ALSO, THE TRANSMISSION SUDDENLY WON'T SHIFT FROM 2ND TO 3RD. DEALER DIAGNOSED THE REAR END PROBLEM AS BEARINGS NEEDED TO BE REPLACED AND PROBABLY THE REAR HUBS WERE BAD. THE TRANSMISSION WAS BAD, AND NEEDED TO BE REPLACED. FORD DEALER SERVICE ADVISED ME TO CONTACT FORD 800 NUMBER, AND OPERATOR AFTER PUTTING ME ON HOLD AND TALKING TO THE DEALER TURNED THE PROBLEM OVER TO THE NEXT LEVEL OF CUSTOMER CAR BECAUSE HER LIMIT OF $500 WOULD NOT BEGIN TO COVER THE REPAIRS. FORD COSTUMER CARE CALLED ME AND AFTER LETTING ME TELL MY STORY SAID THERE WAS NO PROGRAM DOLLARS AVAILABLE FOR ASSISTING IN FIXING EITHER PROBLEM, EVEN THOUGH THE REAR END PROBLEM WAS DIRECTLY RELATED TO THE PREVIOUS VISIT AT 74,400 MILES PER THE DEALERS RECOMMENDATION. ALSO INFORMED ME THAT NOT EVEN THE $500 WAS AVAILABLE ,AND THE OPERATOR HAD NO RIGHT TO OFFER THAT AMOUNT. TOOK THE CAR FROM THE DEALER AFTER PAYING $120, PLUS $100 CAR RENTAL THEY WOULD NOT COVE) SINCE THE MILEAGE WAS 400 OVER WARRANTY 75000 MILEAGE LIMIT TO DIAGNOSE A PROBLEM THEY FAILED TO CORRECTLY DIAGNOSE THE FIRST 2 TIMES. *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.

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

RUBBING NOISE IN THE REAR END. DEALER COULD NOT FIND THE CAUSE OF THE PROBLEM AND REPLACED BEARINGS IN THE FRONT LEFT HUB. DEALER SAID 2 OF THE TIRES WERE BADLY CUPPED SO THE COULD NOT HEAR ANY OTHER PROBLEM. PROBLEM/NOISE STILL THERE. *AK

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

MISSING COTTER PINS ON FRONT END UPPER BALL JOINTS. *JB