NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
322 reportsClear category filter134,000 miles · Apr 19, 2005
Engine And Engine CoolingPower TrainSteering
I BROUGHT MY 1996 FORD WINDSTAR IN FOR AN OIL CHANGE, AND WAS TOLD TIE RODS FAILED AND NEEDED TO BE REPLACED. , THEN, NEXT DAY, THEY PHONED AND ADVISED ME THAT TRANSMISSION WAS DEFECTIVE BECAUSE THE PAN WAS FULL OF SHAVINGS, ALSO, POWER STEERING RACK WAS LEAKING, AND INTAKE GASKET NEEDED REPLACEMENT. , A TOTAL OF $5000 TO F…
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I BROUGHT MY 1996 FORD WINDSTAR IN FOR AN OIL CHANGE, AND WAS TOLD TIE RODS FAILED AND NEEDED TO BE REPLACED. , THEN, NEXT DAY, THEY PHONED AND ADVISED ME THAT TRANSMISSION WAS DEFECTIVE BECAUSE THE PAN WAS FULL OF SHAVINGS, ALSO, POWER STEERING RACK WAS LEAKING, AND INTAKE GASKET NEEDED REPLACEMENT. , A TOTAL OF $5000 TO FIX THIS VEHICLE. I BOUGHT IT AT 118,000 MILES, AND THIS HAPPENED SHORTLY AFTER OWNING IT FOR ONE YEAR. CURRENTLY, IT HAS 134,000 MILES, AND CANNOT BE DRIVEN. I PARKED VEHICLE THEN STARTED IT AFTER BEING PARKED FOR A WEEK. HEARD A NOISE FROM FRONT, AND THEN WHITE SMOKE CAME OUT OF THE TAIL PIPE. I DO BELIEVE THAT PAUL CORNIES, THE DEALER THAT I PURCHASED VEHICLE KNEW THAT THEY WERE SELLING ME A LEMON. IT HAS CAUSED ME A LOT OF HARDSHIP AS I NO LONGER WORK DUE TO HEALTH REASONS. I FILED FOR DISABILITY INSURANCE, AND WAS TOLD THAT I HAD A PREEXISTING DISEASE , AND REFUSED TO PAY THE INSURANCE. CURRENTLY, I HAVE A JUNKER IN MY DRIVEWAY THAT I CAN'T AFFORD TO FIX , AND A BILL FOR THE NEXT 3 YEARS, SINCE I STILL OWE FOR IT. I WILL NEVER BUY ANOTHER FORD. *AK
NHTSA ODI #10118128
130,000 miles · Sep 14, 2004
Power Train
WHILE DRIVING THE CONSUMER WAS UNABLE TO SHIFT GEARS. THE CONSUMER WAS ABLE TO PULL OVER AND NOTICED THAT FLUID WAS LEAKING FROM UNDERNEATH THE VEHICLE. THE DEALER INFORMED THE CONSUMER THAT THE TRANSMISSION NEEDED TO BE REPLACED. *JB *NM
NHTSA ODI #10083504
17,000 miles · Mar 5, 2004
Power Train
AUTOMATIC TRANSMISSION HAD BEEN REPLACED FOUR TIMES AT APPROXIMATELY EVERY 17,000 MILES. THE CAUSE OF THE MALFUNCTION OF THE TRANSMISSION WAS NOT DISCLOSED TO THE CONSUMER BY THE DEALER. *AK
NHTSA ODI #10061434
62,000 miles · Jan 15, 2004
Engine And Engine CoolingPower TrainUnknown Or Other
ENGINE: HEAD GASKET FAILURE @ 62,218 MILES. NEEDED TO REPLACE BOTH CYLINDER GASKET HEADS AND RESURFACE SAME. POWER DOOR: FAILURE OF POWER DOOR LOCK ON PASSENGER SIDE. TRANSMISSION: WAS REPLACED TWICE UNDER WARRANTY. OTHER: IGNITION CONTROL MODULE NEEDED REPLACEMENT. HAVE BEEN ADVISED ENGINE HAS A SLUDGE CONDITION DESPITE …
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ENGINE: HEAD GASKET FAILURE @ 62,218 MILES. NEEDED TO REPLACE BOTH CYLINDER GASKET HEADS AND RESURFACE SAME. POWER DOOR: FAILURE OF POWER DOOR LOCK ON PASSENGER SIDE. TRANSMISSION: WAS REPLACED TWICE UNDER WARRANTY. OTHER: IGNITION CONTROL MODULE NEEDED REPLACEMENT. HAVE BEEN ADVISED ENGINE HAS A SLUDGE CONDITION DESPITE REGULAR OIL CHANGES PER FORD GUIDELINES.
NHTSA ODI #10070217
78,000 miles · Jan 15, 2004
Engine And Engine CoolingPower TrainService Brakes, Hydraulic
MY 1996 FORD WINDSTAR VAN'S ENGINE ASSEMBLY MUST BE REPLACED DUE TO PERSISTENT INTERNAL COOLANT LOSS INTO THE ENGINE, DESPITE REPEATED TRIPS TO THE DEALERSHIP WITH COMPLAINTS OF CLASSIC HEAD-GASKET SYMPTOMS. FORD DISPLAYED BLATANT NEGLEGENCE AND DISHONESTY IN ITS DEALINGS WITH ME. I TOOK MY VAN TO DEALERSHIP TWICE FOR HEAD-GAS…
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MY 1996 FORD WINDSTAR VAN'S ENGINE ASSEMBLY MUST BE REPLACED DUE TO PERSISTENT INTERNAL COOLANT LOSS INTO THE ENGINE, DESPITE REPEATED TRIPS TO THE DEALERSHIP WITH COMPLAINTS OF CLASSIC HEAD-GASKET SYMPTOMS. FORD DISPLAYED BLATANT NEGLEGENCE AND DISHONESTY IN ITS DEALINGS WITH ME. I TOOK MY VAN TO DEALERSHIP TWICE FOR HEAD-GASKET-LIKE SYMPTOMS: EXCESSIVE LOSS OF COOLANT WITH NO EXTERNAL LEAKAGE, GRAY SMOKE OUT OF EXHAUST, AND ENGINE RUNNING ROUGH. THE FIRST TIME THE DEALERSHIP SAID NO PROBLEMS COULD BE FOUND. TWO WEEKS LATER I RETURNED TO THE DEALERSHIP WITH THE SAME SYMPTOMS, ONLY THIS TIME MORE OBVIOUS, AND THE CHECK-ENGINE LIGHT HAD COME ON. THE DEALERSHIP DETERMINED MY ENGINE HAD OVERHEATED AND THAT COOLANT WAS LOST VIA THE TIMING COVER GASKET, WHICH THEY REPLACED AND THEN RETURNED THE VEHICLE TO ME. EXACTLY ONE THOUSAND MILES LATER I HAD TO HAVE MY VEHICLE TOWED TO THE DEALERSHIP, AT WHICH POINT THEY CONDEMNED MY ENGINE DUE TO COOLANT ENTERING THE #1 CYLINDAR. THEY OFFERED TO REPLACE THE ENGINE FOR $3,650, WHICH INCLUDES A 20% DISCOUNT FOR THE TIMING COVER GASKET WORK THAT WAS DONE FOR NOTHING. I REFUSED THE OFFER AND MANAGED TO BARELY DRIVE THE VEHICLE HOME, WHERE IT NOW SITS, UNDRIVABLE. AWARE OF THE WINDSTAR HEAD GASKET PROBLEMS FROM THE BEGINNING, I REPEATEDLY STRESSED TO THE DEALERSHIP MY CONCERN THAT THIS WAS A HEAD GASKET PROBLEM, BUT THEY REPEATEDLY EXPLAINED THIS WAS NOT THE PROBLEM. THEY LIED BY SAYING NO KNOWN GASKET PROBLEMS EXIST ON THE 1996 WINDSTAR, BUT I RESEARCHED THE NHTSA'S RECORDS AND FOUND TSB 99-13-1 (TITLED "UNDERDETERMINED LOSS OF COOLANT"), WHICH INSTRUCTS DEALERSHIPS TO REPLACE THE GASKETS IN SITUATIONS LIKE MINE. THE TSB IS VERY CLEAR. I WROTE THE DEALERSHIP A LETTER DEMANDING HELP REPLACING THE ENGINE, BUT RECEIVED NO REPLY. I RE-SENT THE SAME LETTER AND DOCUMENTS TO THE DEALERSHIP JUST YESTERDAY. I CAN PROVIDE COPIES OF ALL DOCUMENTS, AS I HAVE SCANNED THEM INTO A COMPRESSED PDF FILE FOR E-MAIL TRANSMISSION.
NHTSA ODI #10070177
88,580 miles · Jan 15, 2004
Engine And Engine CoolingPower Train
CHECK ENGINE LIGHT ON, WHITE SMOKE EMITTING FROM TAILPIPE, MISSING, WILDLY ERRATIC SPEEDOMETER AT 35-40, REAR AIR BLOWS HOT. REPLACEMENTS: HAD GASKETS, LOWER INTAKE GASKETS, UPPER INTAKE GASKETS, SPARK PLUGS, WIRES, THERMOSTAT, GASKET, ? BELT, TIMING COVER, TIMING COVER GASKET, WATER PUMP. SPEEDOMETER AND A/C PROBLEM NOT YET …
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CHECK ENGINE LIGHT ON, WHITE SMOKE EMITTING FROM TAILPIPE, MISSING, WILDLY ERRATIC SPEEDOMETER AT 35-40, REAR AIR BLOWS HOT. REPLACEMENTS: HAD GASKETS, LOWER INTAKE GASKETS, UPPER INTAKE GASKETS, SPARK PLUGS, WIRES, THERMOSTAT, GASKET, ? BELT, TIMING COVER, TIMING COVER GASKET, WATER PUMP. SPEEDOMETER AND A/C PROBLEM NOT YET FIXED.
NHTSA ODI #10070140
Mileage unknown · Jan 15, 2004
Engine And Engine CoolingPower TrainSteering
12-15-97 AT 21,145 MILES I REPORTED NOTICING THE COOLANT LEVEL ALWAYS BEING LOW. NO LEAK WAS FOUND AND I WAS TOLD THERE MUST BE A LEAK SOMEWHERE IN THE RADIATOR. 12-27-99 AT 56,526 MILES I BEGAN HAVING A "COLD START" PROBLEM. IT ACTED LIKE IT WAS NOT GETTING FUEL. 12-1200 AT 74,306 MILES I HAD THE SAME "COLD STAR…
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12-15-97 AT 21,145 MILES I REPORTED NOTICING THE COOLANT LEVEL ALWAYS BEING LOW. NO LEAK WAS FOUND AND I WAS TOLD THERE MUST BE A LEAK SOMEWHERE IN THE RADIATOR. 12-27-99 AT 56,526 MILES I BEGAN HAVING A "COLD START" PROBLEM. IT ACTED LIKE IT WAS NOT GETTING FUEL. 12-1200 AT 74,306 MILES I HAD THE SAME "COLD START" PROBLEM AND THE FUEL FILTER WAS REPACED. 12-22-00 AT 74,930 A NEW THERMOSTAT & GASKET. 12-29-00 AT 75,113 A FUEL PRESSURE REGULATOR. 03-02-01 AT 77,569 MILES A NEW FUEL PUMP RELAY(CCRM), FUEL PUMP AND PVC VALVE. 09-11-01 AT 87,907 MILES A MULT-FUNCTION SWITCH. 01-31-02 AT 95,069 MILES A SECOND CCRM RELAY. 03-06-02 AT 99,348 MILES ON AN 80 DEGREE DAY "NO START" SAME SYMPTOMS AS "COLD START" PROBLEM. INSTEAD OF NOT GETTING FUEL IT IS SUSPECTED IT IS FLOODING. 4-23-02 AT 99,348 MILES COLD START PROBLEM, FUEL INJECTORS CLEANED. 05-30-02 AT 101,330 MILES WOULDN'T START, NO FUEL PRESSURE-INTERMITTENT. HAD TO HAVE IT TOWED. 6-7-02 AT 101,388 MILES "NO START" PROBLEM. NEW FUEL FILTER, FUEL PUMP AND SENDER O-RING. 12-01-2-01 109,530 MILES VAN STARTED STEAMING - APPEARED TO BE A COOLANT LEAK OR BROKEN HOSE. ADDED COOLANT DIRECT IN RADIATOR. I HAVE CARRIED OWN COOLANT AND ADDED FREQUENLTY SINCE 1997, WHEN I WAS TOLD THERE MUST BE A LEAK IN THE RADIATOR. I COULD NOT FIND ANY TRACE OF SUCH A LEAK BY PUTTING CARDBOARD UNDER VAN. SUSPECTED THE PLASTIC COOLANT CONTAINER HAD A LEAK. NO COOLANT LEAKS WHERE EVER FOUND DURING ROUTINE OIL CHANGES. 12-04-02 109,568 M,ILES FOUND LEAKING FRONT TIMING COVER GASKET. REPLACED HEADGASKET AND ALL ELSE THAT GOES WITH IT. COST OF REPAIR $1,915.21. I BELIEVE THE HEADGASKET DEFECT HAS BEEN THE PROBLEM ALL A LONG, COSTING ME A SMALL FORTUNE.
NHTSA ODI #10069811
116,786 miles · Nov 10, 2003
Power Train
1996 FORD WINDSTAR AUTO TRANSMISSION FAILURE. INTERMITTENTLY WILL LOCK IN 1ST OR 2ND GEAR SHIFTING UP. ALSO TRANSMISSION, INTERMITTENTLY WILL DOWN SHIFT INTO 2ND GEAR WHILE CRUSING AT 60-70 MPH. THIS SOMETIMES LASTS HOURS AND THEN FOR NO APPARENT REASON DESIDES TO SHIFT ABSOLUTLY FINE. I HAVE CHANGED THE FLUID, FILTER AND GASKET…
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1996 FORD WINDSTAR AUTO TRANSMISSION FAILURE. INTERMITTENTLY WILL LOCK IN 1ST OR 2ND GEAR SHIFTING UP. ALSO TRANSMISSION, INTERMITTENTLY WILL DOWN SHIFT INTO 2ND GEAR WHILE CRUSING AT 60-70 MPH. THIS SOMETIMES LASTS HOURS AND THEN FOR NO APPARENT REASON DESIDES TO SHIFT ABSOLUTLY FINE. I HAVE CHANGED THE FLUID, FILTER AND GASKET. INTERNALLY LOOKS VERY CLEAN MINUSCULE AMOUNTS OF FILINGS AND NO APPARENT CONTAMINATION. I WOULD LIKE TO KNOW WHAT COMPUTER MODULES AND OR SENSERS ARE INVOLVED. I HAVE HEARD OF THE,TRANSMISSION CONTROL MODULE (TCM) AND THE-----(PCM)?...WHAT ARE THIS ? WHAT IS THEIR PURPOSE? ARE THERE OTHERS?WHERE ARE THEY LOCATED?WHAT DO THEY COST? I CANNOT BELEIVE THE TRANSMISSIONS NEEDS A $2000 REBUILD WHEN IT PERFORMS PERFECTLY MOST OF THE TIME. LOGIC CONVINCES ME IT MAY VERY WELL BE AS SIMPLE AS PLUG AND PLAY. YET NO TRANSMISSION SHOPS WANT TO HEAR OF IT, THEY WANT TO REBUILD. MY COMPLAINT IS NOT WITH THE EQUIPTMENT BUT WITH THE EXPERTS , ESPECIALLY THE DEALERS TAKING ADVANTAGE OF CUSTOMERS. CASE IN POINT, THE HEAD GASKET BLEW OUT ON THE WINDSTAR DEALER PRICED THE REPAIR NO LESS THAN $1450.00 AND NOT TO BE SURPRISED AT FINAL COST UPWARDS OF $2200.00. I HAD IT TOWED 70 MILES TO MY LOCAL MECHINIC AND THE COSTS INCLUDING THE TOW JOB WAS $237.00. I WISH HE WAS A TRANSMISSION MECH. BUT HE IS NOT.YOU HAVE MY E-MAIL ADDRESS I ASSUME YOU WANTED THAT TO HELP ME. ANSWER MY QUESTIONS ABOUT THE COMPUTER MODULE ETC..AND PLEASE DO NOT GIVE MY ADDRESS TO ANY OTHER SITES FOR THAT MATTER TO ANYONE AT ALL. DO THIS, YOU WILL EARN MY TRUST, I WILL BE GREATFUL, YOU JUST NEED TO ASK.*AK
NHTSA ODI #10045897
103,289 miles · Oct 30, 2003
Power Train
AUTOMATIC TRANSMISSION FAILURE POSSIBLY DUE TO LOW TRANSMISSION FLUID FOLLOWING GUIDELINES IN OWNERS GUIDE . AFTER FAILURE AND SUBSEQUENT REPLACEMENT. I FOUND AN ARTICLE IN NEWSPAPER QUOTED FROM FORD REGARDING FLUID LEVEL MAINTENANCE WHICH WAS DIFFERENT THAN RECOMMENDATION IN THE OWNERS GUIDE. *LA
NHTSA ODI #10045131
Mileage unknown · Oct 27, 2003
Power Train
WHEN STOPPED AT STOP SIGN, VAN HESITATED TO SHIFT INTO GEAR FOR ABOUT 5-10 SECONDS AND THEN JERKED INTO DRIVE. THIS HAPPENED NUMEROUS TIMES..TOOK TO DEALER AND THEY COULDN'T TELL ME WHAT WAS WRONG, JUST THAT IT NEEDED TO BE REPLACED. HAD TRANSMISSION OVERHAULED...$1800 THAT I DIDN'T HAVE. 1 YR LATER NOW HAVING MORE PROBLEMS W…
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WHEN STOPPED AT STOP SIGN, VAN HESITATED TO SHIFT INTO GEAR FOR ABOUT 5-10 SECONDS AND THEN JERKED INTO DRIVE. THIS HAPPENED NUMEROUS TIMES..TOOK TO DEALER AND THEY COULDN'T TELL ME WHAT WAS WRONG, JUST THAT IT NEEDED TO BE REPLACED. HAD TRANSMISSION OVERHAULED...$1800 THAT I DIDN'T HAVE. 1 YR LATER NOW HAVING MORE PROBLEMS WITH TRANSMISSION, WHEN GOING AROUND CORNERS VAN SEEMS TO SLIP INTO NEUTRAL UNTIL IT'S STRAIGHTENED OUT. WHEN PROCEEDING FROM A STOP AT A LIGHT OR STOP SIGN, VEHICLE FEELS LIKE IT'S SPINNING THE TIRES, BUT THE POWER ISN'T GETTING THE TIRES, AFTER LETTING OFF THE GAS IT MOVES, BUT THIS IS VERY HAZARDOUS, ESPECIALLY IN HEAVY TRAFFIC..WILL BE TAKING THE VAN TO GET FIXED....AGAIN. NO MORE FORDS FOR ME!!!!*AK
NHTSA ODI #10043645
Official recalls
8Oct 13, 2009
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence & remedy
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
Apr 4, 2002
ON CERTAIN MINIVANS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. DURING ASSEMBLY, SOME BRAKE LINES WERE INSTALLED IN A TWISTED POSITION, CAUSING CONTACT WITH THE DASH PANEL INSULATOR ABOVE THE CATALYTIC CONVERTER. THIS CONTACT COULD ABRADE THE BRAKE LINE CORROSION PROTECTION, CONSEQUENTLY, SALT OR WATER ABSORBED IN THE DASH PANEL INSULATOR WOULD PROMOTE CORROSION. THIS CORROSION COULD ULTIMATELY LEAD TO A LEAK IN THE BRAKE LINE.
Consequence & remedy
Consequence: LEAKAGE OF BRAKE FLUID WILL RESULT IN BRAKE LIGHT ACTIVATION. EXTENDED STOPPING DISTANCE COULD ALSO RESULT, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE BRAKE LINE FOR CORROSION AND CLEARANCE CONDITIONS. A BRAKE LINE THAT IS NOT CORRODED WILL BE REPOSITIONED. A BRAKE LINE THAT IS CORRODED OR LEAKING WILL BE REPLACED WITH A NYLON COATED BRAKE LINE AND SECURED USING THREE RETAINING CLIPS TO ASSURE CLEARANCE FROM THE INSULATOR. OWNER NOTIFICATION BEGAN MAY 10, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
Jun 19, 2000
VEHICLE DESCRIPTION: MINI VANS, LIGHT PICKUP TRUCKS, AND SPORT UTILITY VEHICLES. OFF LEASE CANADIAN VEHICLES EQUIPPED WITH DAYTIME RUNNING LIGHTS WHICH MEET CANADIAN REQUIREMENTS AND NOT THE PHOTOMETRIC REQUIREMENTS OF FMVSS 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." ACCORDING TO FORD, THE VEHICLES WERE IMPORTED INTO THE U.S. ERRONEOUSLY.
Consequence & remedy
Consequence: THE LIGHT GIVEN OFF FROM THE DAYTIME RUNNING LIGHTS IS BRIGHTER THAN ALLOWED BY U.S. STANDARDS.
Remedy: DEALERS WILL BE ADVISED TO DEACTIVATE THE RUNNING LIGHT FUNCTION AND TO COMPLETE ANY OUTSTANDING SAFETY RECALLS ON THESE VEHICLES.
Jun 14, 1999
VEHICLE DESCRIPTION: MINIVANS. THE BRAKE FLUID MASTER CYLINDER IS RECESSED AND ORIENTED IN THE ENGINE COMPARTMENT SO THAT THE BRAKE FLUID WARNING STATEMENT EMBOSSED ON BOTH THE TOP OF THE FILLER CAP AND THE SIDE OF THE RESERVOIR BODY ARE NOT ENTIRELY VISIBLE BY DIRECT VIEW. THESE VEHICLES MAY NOT FULLY COMPLY WITH REQUIREMENTS OF FMVSS NO. 135, "PASSENGER CAR BRAKE SYSTEMS."
Consequence & remedy
Consequence: Not supplied
Remedy: OWNERS WILL BE PROVIDED WITH NEW LABELS AND INSTALLATION INSTRUCTIONS.
Oct 20, 1997
VEHICLE DESCRIPTION: PASSENGER VEHICLES AND MINI VANS. TEARING OF THE BOND BETWEEN THE INNER AND OUTER HOOD PANELS DURING MINOR FRONT END COLLISIONS CAN RESULT IN A GAP AT THE LEADING EDGE OF THE HOOD. AIR FORCED BETWEEN THE INNER AND OUTER PANELS CAN PRODUCE ENOUGH PRESSURE TO FORCE THE OUTER PANEL UPWARD.
Consequence & remedy
Consequence: THIS CONDITION CAN RESULT IN TOTAL SEPARATION OF THE OUTER HOOD PANEL.
Remedy: DEALERS WILL INSPECT THE HOOD AREA FOR ANY DAMAGE ALONG THE LEADING EDGE OF THE HOOD. IF THERE IS ANY EVIDENCE OF BOND SEPARATION, THE HOOD WILL BE REPLACED. IF THERE IS NO EVIDENCE OF BOND SEPARATION, ADDITIONAL ADHESIVE WILL BE APPLIED BETWEEN THE INNER AND OUTER HOOD PANELS.
Sep 5, 1996
THE PARK PAWL ABUTMENT BRACKET HAS A SHARP EDGE WHICH CAN CAUSE THE PARKING PAWL TO HANG UP AND NOT ENGAGE THE PARK GEAR. THIS WOULD ALLOW THE VEHICLE TO MOVE EVEN THOUGH THE GEAR SHIFT INDICATOR SHOWS THAT THE VEHICLE IS IN PARK.
Consequence & remedy
Consequence: UNINTENDED AND UNEXPECTED VEHICLE MOVEMENT CAN RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE.
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE PARK PAWL ABUTMENT BRACKET.
Jul 1, 1996
THE FOUR FASTENERS SECURING THE DRIVER'S SEAT TO THE FLOORPAN WERE NOT TORQUED TO PROPER SPECIFICATIONS.
Consequence & remedy
Consequence: THE DRIVER'S SEAT MAY NOT PROPERLY HOLD IN THE EVENT OF A VEHICLE ACCIDENT RESULTING IN PERSONAL INJURY TO THE OCCUPANT.
Remedy: DEALERS WILL INSPECT THE DRIVER'S SEAT FASTENERS AND RETORQUE TO PROPER SPECIFICATIONS.
May 14, 1996
THE PARK PAWL SHAFT WAS IMPROPERLY POSITIONED WHEN THE ROLL PIN THAT RETAINS IT WAS INSTALLED DURING TRANSMISSION ASSEMBLY. IF THE SHAFT WAS NOT PROPERLY POSITIONED, THE ROLL PIN MAY NOT HAVE LINED UP WITH THE GROOVE IN THE SHAFT AND HAVE BEEN CRUSHED AT ASSEMBLY. ALSO, A BURR COULD HAVE BEEN RAISED ON THE SHAFT.
Consequence & remedy
Consequence: THIS COULD RESULT IN THE PARK PAWL OCCASIONALLY NOT ENGAGING WHEN THE TRANSMISSION SELECTOR LEVER IS PLACED IN THE PARK POSITION. THIS COULD RESULT IN THE VEHICLE ROLLING AS IF IN NEUTRAL IF THE VEHICLE OPERATOR DOES NOT APPLY THE PARKING BRAKE.
Remedy: DEALERS WILL INSPECT THE PARK PAWL SHAFT ROLL PIN. IF THE ROLL PIN IS DAMAGED, BOTH THE ROLL PIN AND THE PARK PAWL SHAFT WILL BE REPLACED. IN ADDITION, OWNERS WILL BE REMINDED TO FULLY APPLY THE PARKING BRAKE, IN ADDITION TO PLACING THE TRANSMISSION IN PARK.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
13EA08021 · Engine Compartment Fires
Opened Sep 17, 2008 · Closed Oct 14, 2009
Status: closed (inferred from source dates) · Electrical System; Electrical System:wiring; Service Brakes, Hydraulic; Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip; Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module ; Vehicle Speed Control; Vehicle Speed Control:cruise Control
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Additional source detail variants (7)
Electrical System
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Electrical System:wiring
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Service Brakes, Hydraulic
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Vehicle Speed Control:cruise Control
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
Vehicle Speed Control
EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.
PE08035 · Engine Compartment Fires
Opened May 13, 2008 · Closed Sep 17, 2008
Status: closed (inferred from source dates) · Electrical System; Electrical System:wiring; Vehicle Speed Control
ODI HAS RECEIVED 134 CONSUMER COMPLAINTS, 285 MANUFACTURER COMPLAINTS, AND 137 MANUFACTURER WARRANTY CLAIMS ALLEGING INCIDENTS OF ENGINE COMPARTMENT FIRE IN MODEL YEAR (MY) 1995 THRU 2003 FORD WINDSTAR VEHICLES.TWO OF THE ODI COMPLAINTS ALLEGE THE FIRES CAUSED STRUCTURAL DAMAGE TO THE COMPLAINANT'S HOME.OF THE 134 ODI COMPLAINTS, 36 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS PARKED, 72 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS RUNNING AND 26 OF THE COMPLAINTS DO NOT SPECIFY IF THE VEHICLE WAS RUNNING OR NOT.FURTHER REVIEW OF THE ODI COMPLAINTS SHOWS THAT 72 ALLEGE THAT THE SPEED CONTROL DEACTIVATION SWITCH (SCDS) CAUSED THE FIRE AND 10 ALLEGE THAT THE SCDS LEAKED BRAKE FLUID ON TO THE ABS MODULE RESULTING IN THE FIRE.THERE WERE 52 THAT DID NOT IDENTIFY A CAUSE OR THAT IDENTIFIED MISCELLANEOUS OTHER CAUSES.ODI HAS ALSO RECEIVED 89 COMPLAINTS ( NOT COUNTED IN THIS RESUME) ALLEGING THAT THE SCDS DEVELOPED A BRAKE FLUID LEAK.THIRTEEN OF THESE COMPLAINTS SAY THAT THE LEAK AT THE SCDS RESULTED IN BRAKED FLUID REACHING THE ABS MODULE.THIS PE HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA) TO FURTHER EVALUATE THE CAUSE OF THE FIRES AND ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.
Additional source detail variants (3)
Electrical System
ODI HAS RECEIVED 134 CONSUMER COMPLAINTS, 285 MANUFACTURER COMPLAINTS, AND 137 MANUFACTURER WARRANTY CLAIMS ALLEGING INCIDENTS OF ENGINE COMPARTMENT FIRE IN MODEL YEAR (MY) 1995 THRU 2003 FORD WINDSTAR VEHICLES.TWO OF THE ODI COMPLAINTS ALLEGE THE FIRES CAUSED STRUCTURAL DAMAGE TO THE COMPLAINANT'S HOME.OF THE 134 ODI COMPLAINTS, 36 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS PARKED, 72 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS RUNNING AND 26 OF THE COMPLAINTS DO NOT SPECIFY IF THE VEHICLE WAS RUNNING OR NOT.FURTHER REVIEW OF THE ODI COMPLAINTS SHOWS THAT 72 ALLEGE THAT THE SPEED CONTROL DEACTIVATION SWITCH (SCDS) CAUSED THE FIRE AND 10 ALLEGE THAT THE SCDS LEAKED BRAKE FLUID ON TO THE ABS MODULE RESULTING IN THE FIRE.THERE WERE 52 THAT DID NOT IDENTIFY A CAUSE OR THAT IDENTIFIED MISCELLANEOUS OTHER CAUSES.ODI HAS ALSO RECEIVED 89 COMPLAINTS ( NOT COUNTED IN THIS RESUME) ALLEGING THAT THE SCDS DEVELOPED A BRAKE FLUID LEAK.THIRTEEN OF THESE COMPLAINTS SAY THAT THE LEAK AT THE SCDS RESULTED IN BRAKED FLUID REACHING THE ABS MODULE.THIS PE HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA) TO FURTHER EVALUATE THE CAUSE OF THE FIRES AND ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.
Electrical System:wiring
ODI HAS RECEIVED 134 CONSUMER COMPLAINTS, 285 MANUFACTURER COMPLAINTS, AND 137 MANUFACTURER WARRANTY CLAIMS ALLEGING INCIDENTS OF ENGINE COMPARTMENT FIRE IN MODEL YEAR (MY) 1995 THRU 2003 FORD WINDSTAR VEHICLES.TWO OF THE ODI COMPLAINTS ALLEGE THE FIRES CAUSED STRUCTURAL DAMAGE TO THE COMPLAINANT'S HOME.OF THE 134 ODI COMPLAINTS, 36 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS PARKED, 72 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS RUNNING AND 26 OF THE COMPLAINTS DO NOT SPECIFY IF THE VEHICLE WAS RUNNING OR NOT.FURTHER REVIEW OF THE ODI COMPLAINTS SHOWS THAT 72 ALLEGE THAT THE SPEED CONTROL DEACTIVATION SWITCH (SCDS) CAUSED THE FIRE AND 10 ALLEGE THAT THE SCDS LEAKED BRAKE FLUID ON TO THE ABS MODULE RESULTING IN THE FIRE.THERE WERE 52 THAT DID NOT IDENTIFY A CAUSE OR THAT IDENTIFIED MISCELLANEOUS OTHER CAUSES.ODI HAS ALSO RECEIVED 89 COMPLAINTS ( NOT COUNTED IN THIS RESUME) ALLEGING THAT THE SCDS DEVELOPED A BRAKE FLUID LEAK.THIRTEEN OF THESE COMPLAINTS SAY THAT THE LEAK AT THE SCDS RESULTED IN BRAKED FLUID REACHING THE ABS MODULE.THIS PE HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA) TO FURTHER EVALUATE THE CAUSE OF THE FIRES AND ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.
Vehicle Speed Control
ODI HAS RECEIVED 134 CONSUMER COMPLAINTS, 285 MANUFACTURER COMPLAINTS, AND 137 MANUFACTURER WARRANTY CLAIMS ALLEGING INCIDENTS OF ENGINE COMPARTMENT FIRE IN MODEL YEAR (MY) 1995 THRU 2003 FORD WINDSTAR VEHICLES.TWO OF THE ODI COMPLAINTS ALLEGE THE FIRES CAUSED STRUCTURAL DAMAGE TO THE COMPLAINANT'S HOME.OF THE 134 ODI COMPLAINTS, 36 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS PARKED, 72 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS RUNNING AND 26 OF THE COMPLAINTS DO NOT SPECIFY IF THE VEHICLE WAS RUNNING OR NOT.FURTHER REVIEW OF THE ODI COMPLAINTS SHOWS THAT 72 ALLEGE THAT THE SPEED CONTROL DEACTIVATION SWITCH (SCDS) CAUSED THE FIRE AND 10 ALLEGE THAT THE SCDS LEAKED BRAKE FLUID ON TO THE ABS MODULE RESULTING IN THE FIRE.THERE WERE 52 THAT DID NOT IDENTIFY A CAUSE OR THAT IDENTIFIED MISCELLANEOUS OTHER CAUSES.ODI HAS ALSO RECEIVED 89 COMPLAINTS ( NOT COUNTED IN THIS RESUME) ALLEGING THAT THE SCDS DEVELOPED A BRAKE FLUID LEAK.THIRTEEN OF THESE COMPLAINTS SAY THAT THE LEAK AT THE SCDS RESULTED IN BRAKED FLUID REACHING THE ABS MODULE.THIS PE HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA) TO FURTHER EVALUATE THE CAUSE OF THE FIRES AND ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.
RQ04003 · Hydraulic Brake Line Failure
Opened May 27, 2004 · Closed Oct 7, 2004
Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:fluid; Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
ON APRIL 4, 2002, FORD MOTOR COMPANY NOTIFIED ODI OF A DEFECT CONDITION THAT COULD RESULT IN EXTENDED STOPPING DISTANCES IN APPROXIMATELY 250 THOUSAND MODEL YEAR (MY) 1995 AND 1996 WINDSTAR MINIVANS SOLD OR REGISTERED IN SALT BELT STATES (RECALL 02V-101).ACCORDING TO FORD, IMPROPER BRAKE LINE ROUTING IN VEHICLES MANUFACTURED AT THE OAKVILLE ASSEMBLY PLANT FROM JANUARY 14, 1994 THROUGH MAY 21, 1996 RESULTED IN SOME VEHICLES WITH MIS-POSITIONED BRAKE LINES THAT COULD CONTACT A DASH PANEL INSULATOR.SUCH CONTACT COULD ABRADE THE BRAKE LINE PROTECTION COATING AND RESULT IN CORROSIVE FAILURE OF THE BRAKE LINES. ODI OPENED RQ04-003 TO INVESTIGATE COMPLAINTS OF BRAKE LINE FAILURE IN WINDSTAR VEHICLES THAT WERE:(1) LOCATED OUTSIDE THE RECALL REGION; OR (2) BUILT AFTER THE RECALL RANGE.REGARDING THE LATTER GROUP, FORD CHANGED THE ASSEMBLY PROCESS AFTER MAY 21, 1996 TO ELIMINATE THE MIS-BUILD PROBLEM.THE FAILURE RATES IN THE MY 1996 WINDSTAR VEHICLES BUILT AFTER THE PROCESS CHANGE ARE RELATIVELY LOW IN BOTH THE SALT-BELT STATES. WITH RESPECT TO THE MY 1995 AND 1996 VEHICLES BUILT DURING THE PERIOD OF CONCERN THAT WERE NOT SOLD OR REGISTERED IN SALT BELT STATES, THE FAILURE RATE IS ALSO LOW.THE RELATED BRAKE LINE WARRANTY CLAIM RATE FOR THOSE VEHICLES IS ALSO LOW. ACCORDINGLY, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED IN THE MY 1995-96 WINDSTAR VEHICLES THAT WERE NOT INCLUDED IN RECALL 02V-101.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (3)
Service Brakes, Hydraulic:fluid
ON APRIL 4, 2002, FORD MOTOR COMPANY NOTIFIED ODI OF A DEFECT CONDITION THAT COULD RESULT IN EXTENDED STOPPING DISTANCES IN APPROXIMATELY 250 THOUSAND MODEL YEAR (MY) 1995 AND 1996 WINDSTAR MINIVANS SOLD OR REGISTERED IN SALT BELT STATES (RECALL 02V-101).ACCORDING TO FORD, IMPROPER BRAKE LINE ROUTING IN VEHICLES MANUFACTURED AT THE OAKVILLE ASSEMBLY PLANT FROM JANUARY 14, 1994 THROUGH MAY 21, 1996 RESULTED IN SOME VEHICLES WITH MIS-POSITIONED BRAKE LINES THAT COULD CONTACT A DASH PANEL INSULATOR.SUCH CONTACT COULD ABRADE THE BRAKE LINE PROTECTION COATING AND RESULT IN CORROSIVE FAILURE OF THE BRAKE LINES. ODI OPENED RQ04-003 TO INVESTIGATE COMPLAINTS OF BRAKE LINE FAILURE IN WINDSTAR VEHICLES THAT WERE:(1) LOCATED OUTSIDE THE RECALL REGION; OR (2) BUILT AFTER THE RECALL RANGE.REGARDING THE LATTER GROUP, FORD CHANGED THE ASSEMBLY PROCESS AFTER MAY 21, 1996 TO ELIMINATE THE MIS-BUILD PROBLEM.THE FAILURE RATES IN THE MY 1996 WINDSTAR VEHICLES BUILT AFTER THE PROCESS CHANGE ARE RELATIVELY LOW IN BOTH THE SALT-BELT STATES. WITH RESPECT TO THE MY 1995 AND 1996 VEHICLES BUILT DURING THE PERIOD OF CONCERN THAT WERE NOT SOLD OR REGISTERED IN SALT BELT STATES, THE FAILURE RATE IS ALSO LOW.THE RELATED BRAKE LINE WARRANTY CLAIM RATE FOR THOSE VEHICLES IS ALSO LOW. ACCORDINGLY, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED IN THE MY 1995-96 WINDSTAR VEHICLES THAT WERE NOT INCLUDED IN RECALL 02V-101.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Service Brakes, Hydraulic
ON APRIL 4, 2002, FORD MOTOR COMPANY NOTIFIED ODI OF A DEFECT CONDITION THAT COULD RESULT IN EXTENDED STOPPING DISTANCES IN APPROXIMATELY 250 THOUSAND MODEL YEAR (MY) 1995 AND 1996 WINDSTAR MINIVANS SOLD OR REGISTERED IN SALT BELT STATES (RECALL 02V-101).ACCORDING TO FORD, IMPROPER BRAKE LINE ROUTING IN VEHICLES MANUFACTURED AT THE OAKVILLE ASSEMBLY PLANT FROM JANUARY 14, 1994 THROUGH MAY 21, 1996 RESULTED IN SOME VEHICLES WITH MIS-POSITIONED BRAKE LINES THAT COULD CONTACT A DASH PANEL INSULATOR.SUCH CONTACT COULD ABRADE THE BRAKE LINE PROTECTION COATING AND RESULT IN CORROSIVE FAILURE OF THE BRAKE LINES. ODI OPENED RQ04-003 TO INVESTIGATE COMPLAINTS OF BRAKE LINE FAILURE IN WINDSTAR VEHICLES THAT WERE:(1) LOCATED OUTSIDE THE RECALL REGION; OR (2) BUILT AFTER THE RECALL RANGE.REGARDING THE LATTER GROUP, FORD CHANGED THE ASSEMBLY PROCESS AFTER MAY 21, 1996 TO ELIMINATE THE MIS-BUILD PROBLEM.THE FAILURE RATES IN THE MY 1996 WINDSTAR VEHICLES BUILT AFTER THE PROCESS CHANGE ARE RELATIVELY LOW IN BOTH THE SALT-BELT STATES. WITH RESPECT TO THE MY 1995 AND 1996 VEHICLES BUILT DURING THE PERIOD OF CONCERN THAT WERE NOT SOLD OR REGISTERED IN SALT BELT STATES, THE FAILURE RATE IS ALSO LOW.THE RELATED BRAKE LINE WARRANTY CLAIM RATE FOR THOSE VEHICLES IS ALSO LOW. ACCORDINGLY, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED IN THE MY 1995-96 WINDSTAR VEHICLES THAT WERE NOT INCLUDED IN RECALL 02V-101.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
ON APRIL 4, 2002, FORD MOTOR COMPANY NOTIFIED ODI OF A DEFECT CONDITION THAT COULD RESULT IN EXTENDED STOPPING DISTANCES IN APPROXIMATELY 250 THOUSAND MODEL YEAR (MY) 1995 AND 1996 WINDSTAR MINIVANS SOLD OR REGISTERED IN SALT BELT STATES (RECALL 02V-101).ACCORDING TO FORD, IMPROPER BRAKE LINE ROUTING IN VEHICLES MANUFACTURED AT THE OAKVILLE ASSEMBLY PLANT FROM JANUARY 14, 1994 THROUGH MAY 21, 1996 RESULTED IN SOME VEHICLES WITH MIS-POSITIONED BRAKE LINES THAT COULD CONTACT A DASH PANEL INSULATOR.SUCH CONTACT COULD ABRADE THE BRAKE LINE PROTECTION COATING AND RESULT IN CORROSIVE FAILURE OF THE BRAKE LINES. ODI OPENED RQ04-003 TO INVESTIGATE COMPLAINTS OF BRAKE LINE FAILURE IN WINDSTAR VEHICLES THAT WERE:(1) LOCATED OUTSIDE THE RECALL REGION; OR (2) BUILT AFTER THE RECALL RANGE.REGARDING THE LATTER GROUP, FORD CHANGED THE ASSEMBLY PROCESS AFTER MAY 21, 1996 TO ELIMINATE THE MIS-BUILD PROBLEM.THE FAILURE RATES IN THE MY 1996 WINDSTAR VEHICLES BUILT AFTER THE PROCESS CHANGE ARE RELATIVELY LOW IN BOTH THE SALT-BELT STATES. WITH RESPECT TO THE MY 1995 AND 1996 VEHICLES BUILT DURING THE PERIOD OF CONCERN THAT WERE NOT SOLD OR REGISTERED IN SALT BELT STATES, THE FAILURE RATE IS ALSO LOW.THE RELATED BRAKE LINE WARRANTY CLAIM RATE FOR THOSE VEHICLES IS ALSO LOW. ACCORDINGLY, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED IN THE MY 1995-96 WINDSTAR VEHICLES THAT WERE NOT INCLUDED IN RECALL 02V-101.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
RQ02011 · Fuel Tank Fatigue Cracking
Opened Aug 29, 2002 · Closed Mar 14, 2003
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly
SEE ATTACHED REPORT.
EA00027 · Suspension Coil Spring Breakage
Opened Dec 8, 2000 · Closed Jul 31, 2001
Status: closed (inferred from source dates) · Suspension
There is no summary currently available
Additional source detail variants (2)
Suspension
There is no summary currently available
Suspension
There is no summary currently available
PE00024 · Suspension Coil Spring Breakage
Opened Jun 23, 2000 · Closed Dec 8, 2000
Status: closed (inferred from source dates) · Suspension
There is no summary currently available
EA99020 · Fuel Tank Cracks
Opened Jul 26, 1999 · Closed Dec 16, 1999
Status: closed (inferred from source dates) · Fuel System, Gasoline
There is no summary currently available
PE98056 · Rear Axle Trailing Arm
Opened Oct 28, 1998 · Closed Feb 24, 1999
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
EA97018 · Outer Hood Panel Detachment
Opened Sep 30, 1997 · Closed Oct 22, 1997
Status: closed (inferred from source dates) · Structure
There is no summary currently available
PE97011 · Outer Hood Panel Detachment
Opened Mar 13, 1997 · Closed Sep 30, 1997
Status: closed (inferred from source dates) · Structure
THE OFFICE OF DEFECTS INVESTIGATION HAS RECEIVED 6 REPORTS INDICATING THE OUTER HOOD PANEL SEPARATED FROM THE VEHICLES AS THEY WERE BEING DRIVEN.FORD HAS PROVIDE 39 ADDITIONAL REPORTS THAT ARE CONSISTENT WITH ODI REPORTS.FORD INDICATES THAT THE LIKELY CAUSE IS PRIOR COLLISION DAMAGE.THIS INVESTIGATION IS BEING UPGRADED TO FURTHER STUDY THIS ISSUE.
EA96026 · Brake Pedal Fade/extended Stop Distance
Opened Oct 31, 1996 · Closed Feb 18, 2000
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
There is no summary currently available
PE96042 · Brake Pedal Fade/extended Stopping
Opened Jun 13, 1996 · Closed Oct 31, 1996
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
ODI HAS RECEIVED SIXTY-EIGHT (68) CONSUMER REPORTS OF ALLEGED FAILURES OR MALFUNCTIONS IN THE BRAKE SYSTEM ON CERTAIN 1995 AND 1996 FORD WINDSTARS, WHICH RESULTED IN BRAKE PEDAL FADE AND IN EXTENDED STOPPING DISTANCES DURING BRAKINGTHESE ALLEGED FAILURES OR MALFUNCTIONS ARE REPORTED TO HAVE CAUSED TWELVE (12) ACCIDENTS THAT RESULTED FROM VEHICLE LOSS OF BRAKING.THE CONPLAINANTS REPORT THAT THE LOSS OF BRAKING OCCURRED DURINGBRAKING SITUATIONS ON DRY ROADS AS WELL AS ON WET OR SLIPPERY ROADS.IN RESPONSE TO ODI'S INFORMATION REQUES (IR) CONCERNING THE LONG STOPPING DISTANCE COMPLAINTS ON THE 1995 WINDSTAR, FORD REPORTED RECEIVING 259 REPORT (FIELD REPORTS, OWNER COMPLAINTS, AND SUBROGATION CLAIMS) OF LONG STOPPING DISTANCE ON THE 1995 FORD WINDSTAR, ALONG WITH 64 REPORTS OF ACCIDENTS.IN ADDITION, FORD REPORTED RECEIVING SOME 64,000 WARRANTY CLAIMS THAT COULD RELATE TO THE ALLEGED DEFECT OF LONG STOPPING DISTANCE PERFORMANCE ON THE SUBJECT VEHICLES.SINCE APRELIMINARY EVALUATION WAS OPENED, ODI HAS RECEIVED ADDITIONAL COMPLAINTS OF THE ALLEGED FAILURE ON THE 1996 MODELS, WHICH WERE NOT INCLUDED INITIALLY IN THIS INVESTIGATION.ODI BELIEVES THAT AN ENGINEERING ANALYSIS ON THE 1995 AND 1996 FORD WINDSTAR VEHICES IN WARRANTED TO DETERMINE THE SCOPE OF THE PROBLEM.
PE96015 · Failure Of Auto Trans Park Lock System
Opened Feb 23, 1996 · Closed May 22, 1996
Status: closed (inferred from source dates) · Power Train:automatic Transmission
THE MANUFACTURER HAS NOTIFIED NHTSA THAT THE SUBJECT VEHICLES WILL BE RECALLED TO CORRECT A SAFETY RELATED DEFECT IDENTIFIED UNDER THE SCOPE OF THIS INVESTIGATION.THE DEFECT AFFECTS CERTAIN 1996 MODEL YEAR WINDSTAR, FORD TAURUS, AND MERCURY SABLE VEHICLES EQUIPPED WITH FORD AX4S MODEL AUTOMATIC TRANSMISSIONS.THE SAFETY RECALL ACTION HAS BEEN IDENTIFIED AS NHTSA NO. 96V-086.
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