5 people in my vehicle driving 55mph on I40 around midnight when air suspension went out and everything in the dash went crazy. Things cutting off and on moving backwards and forwards, when I cut it off so to not drive with air suspension down it would not restart unless you started it in neutral but the battery kept dying and exploded driving to shop, .got another battery, it exploded to. Nothing electrical worked. Door locks, windows, speedometer, stereo wouldn't come on then would come on by itself, lights to. Air suspension would not work, been in the shop twice. First time they didn't know what was wrong. This time they know but I can afford to fix it. The GEM module and fuse box is over $600 plus labor! im disabled with a fixed income and I haven't driven anywhere since Feb I cant get to my doctor, grocery store, to get medicine for heart attack and other disabling illnesses. I cant afford another car or to fix my expo. This could have been dangerous I sure need some help with this.electrical system failure NHTSA preliminary evaluation #PE05033 status:closed date opened:June 15, 2005 date closed: October 13, 2005 recall: No recall issued component(s): Electrical system equipment:electrical visibility:windshield summary: ODI has received 39 reports alleging that water leaks around the windshield causing electrical failures, including but not limited to the windshield wipers and the headlamps.Ford reports that water entering the vehicle can wet the power distribution box (pdb) and the generic electronic module (GEM).these components control various electrical systems in the vehicle.this investigation has been upgraded to an engineering analysis, EA05015, to allow further investigation of the issue and to assess the nature of the potential safety consequence.NHTSA: For detailed information & supporting documents, see the official NHTSA investigation#PE05033.

- Nebo, NC, USA

With no warning spare tire cable snapped while driving down road causing spare tire to fall out and strike rear wheel of vehicle, then flew off side of road. Discussion with Ford indicated this is unheard of and they wanted $300+ to repair. Discussions with multiple other shops (not Ford) indicate this does happen with this type of spare mount. Repairs completed for under $150. I am concerned that spare can come out and once loose hit other vehicles or property/persons.

- Beaverdam, VA, USA

I purchased a 2000 Ford Expedition eddie bauer SUV new from a local dealer in the los angeles area. Current mileage is 127,300. This concerns a very serious safety problem that has happened twice since we have owned this vehicle. This vehicle is only used to commute to work, never off-road or abused in any manner. A few months into our ownership, we were traveling on the freeway and going over a overpass at 60 miles an hour the spare tire dropped off the SUV and rolled across four lanes of traffic at night. Luckily, it did not kill someone. Then about 8 or 9 months ago it happened again just backing out of our driveway. Inspecting the problem it is clear the steel cable hoist holding the tire up under the rear is breaking under stress. It is clear this is a design defect and a very real safety issue. We have taken it to the local dealership and I have called their 800 number. They claim the vehicle is outside the warranty period. I say this is a safety issue that Ford should not only fix but should redesign the whole mounting system to better support the tire. The tire and rim should have a positive locking device that securely holds the tire in place so the steel cable hoist is used only to raise and lower the tire when the vehicle is at rest. Ford will not put this in writing. I have filed complaints on this issue here in California with the dmv and other agencies - they are referring me to mediation boards to settle it financially. But the Ford fix of installing another steel cable hoist system is not safe. I am considering a third party mounting system to the outside of the vehicle because I do not want this to happen again. Presently, I am driving without the spare tire because we do not want another Ford fix and it would be unsafe carrying it inside the vehicle. You are my last chance of resolving this safety issue. My next step will be to pursue this complaint directly with the public media. That is how serious I am taking this problem.

- Woodland Hills, CA, USA

Vehicle's radio, heat remained on even with keys out of the ignition.

- Homewood, AL, USA

Spare tire winch cable snapped causing spare tire to detach and bounce away behind the car while driving. Nobody was hurt in this incident, but I believe this is a major safety defect.

- Boca Raton, FL, USA

Customer states pedal button on left of steering wheel is installed backward, dealer removed and reinstalled correctly.

- Washington, DC, USA