1. Chain Snapped in transmission at 20,000 miles., requiring a full rebuild under warranty. $2500 if not covered. I was left stranded for 3 hours on the side of the interstate before I could be picked up by roadside assistance.
2. Heater blows cold air on the coldest night of the year. Only happened once, but I was on a 2.5 hr drive. Repaired under factory warranty.
3. Add battery #2 to car.
4. Starter occasionally will not function (30,000 miles.), then finally won't work at all. Wait for 2 hours for roadside assistance. Repaired under factory warranty. Dealer Response: Was a TSB concerning a faulty resistor.
5. Battery #3 added to car.
6. Alternator fails during a thick fog one night. Lose lights, engine, power steering, O/D off, and power assistance for braking. Vehicle was on another 2.5 hr drive going down a mountain. Wirirng harness replaced under factory warranty.
7. Engine seems to lose approximately 50% of its power during warm weather. Problem remains unfixed even after vehicle is totalled. First dealer insisted the cause was my driving style. Second dealer insisted was catalytic converter, which he replaced under warranty. I found a website in the meantime which described a problem with a valve which activates a shorter set of intake runners (IMRC valve). Third dealer diagnoses and insists is in proper working order.
8. Rear power window will not roll up or down. Switch, wiring, and motor replaced under extended warranty. Window is still problematic until demise of vehicle.
9. Paint chipping and peeling on roof and trunk (40,000 miles or 6/2002). Dealer first agrees to paint car, then declines. Ford Service Management inspects vehicle, then advises can only pay 60% of repairs. The factory corrosion warranty covers for 8 years or 100,000 miles. Ford will not honor this, even though is contained in new car information included with vehicle.
10. Add battery #4 to car.
11. Vehicle is wrecked on 10/26/02. Insurance company agrees to the body shop of my choosing, which was a Ford Dealership with a body shop. Vehicle stayed in repair shop for a month, but noise still comes from the damaged areas.
12. Rear suspension fails completely, failing to compress or release. The suspension had no travel. Carry vehicle to dealer in state where vehicle is registered. Vehicle deemed a total loss. Settlement issued.