Engine Exhaust System problems of the 2002 Ford Explorer Sport Trac

While driving 65 and attempting to pass another vehicle consumer's vehicle failed to go into passing gear. Engine stalled and consumer had to coast to the side of the highway. Once off the road consumer restarted the vehicle and continued driving. The vehicle was towed to the dealer but the technician couldn't find anything wrong. The vehicle was taken back tot he dealer where they replaced the fuel pump, gas tank and air flow sensor. So far the vehicle has been running as it should. The heat shield under the vehicle rattled. The dealer adjusted it. The multifunction switch would not lock in place when using the turn signals.

The vehicle must be driven with the windows down because chemical fumes enter into the passenger's compartment. The dealer inspected the vehicle several times, and could not duplicate or correct the problem. The catalytic converter was replaced and reset but the problem remained the same.

I purchased a Ford Explorer Sport Trac in Dec. 2002. I have been in and out of the service department a number of times. The following is a list of items that I've had repaired under warranty: 1. ) front brakes: a loud rubbing/griding sound became increasingly louder. The first time the service dept. Folks said that it was normal. The next time I brought the car in, they could deny the noise and they subsequently replace one rotor and resurfaced the other. 2. ) rear axle: a broken seal allowed hydroulic fluid to cover inside of the rear wheel causing difficulty in braking. The service dept. Repaired under warranty 3. ) the transfer case for the 4-wheel drive was leaking fluid. The service dept. Repaired under warranty. 4. ) the vehicle stalls a numerous amounts of times (10-15 times) since I've owned it. It stalls while I'm driving at 35 miles per hour, in reverse, day or night. When I go for an errand and park, the vehicle will not start. An hour later, when the tow truck is there, the vehicle start. It drives me crazy!! the service dept. Says they cannot do anything because nothing registers on the computer and they cannot simulate the problem. The last time it happened (08-04-04) merging on to the freeway it stalled. Upon start-up, black smoke poured out of the exhaust and idling was extremely rough. I had it towed to a Ford dealership. The service dept replaced a mass airflow meter under warrenty. The vehicle runs. . . I'll cross my fingers!! my current problem is that the front tires are severly cupping and the front end viberates at 60 mph and over. The vehicle has 25k miles and the tires have been rotated 5 times about every 5k miles. I had the wheels checked for alignment and balance and it is to specifications. The service dept says its normal and to continue with the rotations. The tires are wearing unevenly and prematurely. The tire shop recommends that the shocks and struts be replaced. The service dept does not.