Front Suspension Control Arm problems of the 1998 Ford Expedition

The rear lower and upper control arms have rust holes and or completely rusted through. This is obviously a very big problem with all Expeditions around the same years. Complaints from hundreds if not thousands of owners on forums have the same issue. This will cause a crash and or fatalities if not corrected or found before it is too late. I found mine to be very rusty with holes and also one rusted all the way through after a 400 mile highway trip with my family. This is something that Ford should step up to the plate and recall and fix for Ford owners. This is a reported problem and needs to be repaired by Ford ASAP.

As I was examining the rear brake pads on my truck, I noticed that there was a a hole in the right rear lower control arm. Further examination showed that the protective coating on the control arm had not only failed but was holding moisture and salt against the metal of the control arm. Therefore this lower control arm is also quite thin in one specific area and appears to be in danger of imminent failure. Likewise I found a hole and thin sound metal on the left rear lower control arm. If driven, this vehicle could easily have a major loss of control and a catastrophic accident with loss of lives. I consider this to be a manufacturing defect because the coating that was designed to protect this vulnerable part has actually hastened its failure.

Front wheel control arm sheared off. Consumer noticed a rattle. This hooks sway bar to lower control arm. Contacted dealer who stated there were no recalls. Ford stated warranty expired.

There is an excessive play in the control arm. Driver hears a grinding noise everytime the steering wheel is turned to the left or right during any type of weather or speed.

Excessive suspension problems. Cross member bolts for proper torque were not tight and the cross member and lower control arm bolts were out of the torque specs.