1996 Ford Windstar

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.

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.

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.

SEE ATTACHED REPORT.

THE K FRAME RUSTED OUT WHERE THE CONTROL ARMS MOUNT TO THE FRAME AND THE FRONT DRIVER'S SIDE COIL SPRING BROKE WHILE DRIVING AT 65 MILES PER HOUR ON THE INTERSTATE

NHTSA ID

10782238

Incident

Jun 14, 2015

Mileage

114,500 mi

TL* THE CONTACT OWNS A 1996 FORD WINDSTAR. THE CONTACT STATED THAT THERE WAS A VERY STRONG FUEL ODOR INSIDE AND OUTSIDE THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 240,000.

NHTSA ID

10778214

Incident

Sep 24, 2015

Mileage

240,000 mi

TL* THE CONTACT OWNS A 1996 FORD WINDSTAR. WHILE AT A STOP LIGHT, THE ACCELERATOR PEDAL WAS DEPRESSED BUT THE VEHICLE FAILED TO ACCELERATE ABOVE 20 MPH. THE SERVICE BRAKE WARNING INDICATOR ILLUMINATED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 65,000.

NHTSA ID

10694170

Incident

Mar 6, 2015

Mileage

65,000 mi

ABS LIGHT ON DASHBOARD COMES ON INTERMITTENTLY, AFTER 5 MINUTES OF OPERATION LIGHT WILL COME ON, THEN STAY ON, BUT AFTER SHUT OFF VEHICLE AND START AGAIN LIGHT IS FFF AND COMES BACK ON AFTER FEW MINUTES OF TRAVEL. *TR

NHTSA ID

10549528

Incident

Oct 21, 2013

Mileage

152,000 mi

THIS IS A SECOND CALL FOR HELP FORD CORPORATE WILL NOT EMAIL ME BACK. WILL NOT VERIFY IF PCM HAS BEEN UPDATED. THE VAN ONLY HAS UNDER 59,000 MILES ON IT . IT SHOULD NOT BREAK THIS BAD THIS SOON MAKES ME TELL ANYONE ON SOCIAL MEDIA AND OUR LOCAL NEWS MEDIA AND CLARK HOWARDS TEAM. I DO NOT WANT TO CALL FORD UNLESS IT IS AGREED THE PHONE WILL BE RECORDED FOR COURT PURPOSES. I EVEN ASKED IS THE WOULD LET ME USE THE UPDATER. I SURE DO NOT WANT DON RICH FORD IN VILLA RICA EVER AGAIN. THEY STRIPPED THE SCREW. THAT SET MIN CLEARANCE ON THROTTLE PLATE. NO SHIFTS FUNNY AND SPUTTERS AND TERRIBLE NOISE IN OIL PAN AREA. ROD S KNOCKING. INTERNET HAS TONS OF COMPLAINTS OF PISTONS EXITING ENGINE OIL PAN. *TR

NHTSA ID

10522986

Incident

Jul 2, 2013

Mileage

58,958 mi

DEAR FORD MY MOTHER AND I HAVE BEEN TRYING TO GET ANSWERS FROM THE DEALER AND SINCE THEY GAVE UP. BECAUSE THEY COULD NOT FIX IT RIGHT THE FIRST TIME. EVEN THE SECOND OR THIRD TIME. THE VAN A 1996 WINDSTAR WITH 59,000 MILES ON IT AND IT STARTED THE ENGINE STARTED STALLING, WHEN MAKING SLOW TURNS NOT TOUCHING THE GAS PEDAL LOSES POWER STEERING. MY MOM ALMOST WENT INTO A DITCH TO AVOID A COLLISION WITH ANOTHER CAR. WITH LITTLE INTERNET SEARCHING FOUND HUNDREDS OF VANS WITH SAME PROBLEMS, AND APPEARS THERE IS NOT ONE RESOLVED. AND SINCE THIS HAS GONE ON FOR OVER A MONTH. THE LAST VISIT TO THE FORD DEALER IN AN ATTEMPT TO FIX THE STALLING. . THE IDLE AIR CONTROL VALVE IS NEW, AND MASS AIR FLOW IS CLEAN SUPPOSED TO HAVE BEEN REPLACED ALSO. I CHECKED THE AIR FILTER WAS CLEAN, THE FUEL FILTER IS ORIGINAL SO I REPLACED IT. I STARTED LOOKING AT THE THROTTLE BODY, AND NOTICED THAT THE THROTTLE PLATE SCREW WAS ALL GOUGED UP. WHILE I WAS SITTING IN DRIVE WAY WITH ENGINE RUNNING AND UNLESS FORD ENGINES ARE ONLY GOOD FOR 60,000 MILES, WITH ALL THE STALLING AND LOW ENGINE IDLE THAT KEEPS OIL PRESSURE IN THE ENGINE LUBRICATING THE CRANK SHAFT.!! SO WHEN ENGINE STALLED AT VERY LOW IDLE THERE WAS NO OIL GETTING THROUGH THE ENGINE. THIS ENGINE NOW HAS LOWER END KNOCK, WHICH I VERIFIED BY PULLING VAN ONTO FLOOR RAMPS, TEST DROVE AND CONFIRMED THE PROBLEM, IS CRITICAL. EACH TIME I SLOWED DOWN TO TURN ENGINE STALLED EVERY TIME, LOST POWER STEERING AND BRAKES. I COULD HAVE BEEN KILLED BECAUSE FORD IS IGNORING THIS PROBLEM.. AND THIS ALSO ANSWERS WHY OTHER COMPLAINTS WERE ABOUT ENGINE FAILURES AND VERY EXPENSIVE REPAIRS. THIS LETTER WILL BE PUT ON ALL SOCIAL NETWORKS, TO WARN OTHERS THIS COULD HAPPEN TO THEM BE AWARE. THEY SAID THE ECU/PCM COMPUTER WAS UPDATED. COULD NOT FIND UPDATE ON INVOICES, OR IN HISTORY I CAN ACCESS. *TR

NHTSA ID

10522406

Incident

Jun 4, 2013

Mileage

58,586 mi

FORD RECALL LETTER DATED DECEMBER 2011 RECALL NUMBER 09 S 09 SPEED CONTROL SYSTEM MODIFICATION. I RECENTLY TOOK MY FORD WINDSTAR ON JANURARY 3, 2013 FOR A RECALL. ABOUT A MONTH LATER I DROVE OVER RAILROAD TRACKS AND NOW THE VEHICLE IS SLOW AND WON'T PICK UP SPEED IT MAKES A PUT PUT SOUND AND HAS ALMOST NO POWER. I CALLED THE DEALER TO REPORT THE ISSUE AND THEY WANT $90.00 JUST TO LOOK AT IT EVEN THOUGH IT WAS JUST IN THE SHOP FOR THE RECALL. I CALLED FORD CUSTOMER COMPLAINT AND ALL THEY SAY IS THEY ARE NOT RESPONSIBLE FOR THE FORD DEALER ACTIONS OR INACTIONS. THE LETTER FROM FORD WAS THE MAIN REASON I TOOK THE VAN IN BECAUSE IT SAYS THERE IS A FIRE HAZARD BUT NOW THE VAN IS A PIECE OF JUNK. FORD REFUSES TO RECHECK THE VEHICLE AND LOCATE THE REAL CAUSE OF THE PROBLEM THE VEHICLE IS THE ONLY WAY FOR ME TO GET AROUND. THANKS FORD FOR YOUR ATTENTION AND LACK OF CONCERN. SIGNED DISSATIFIED VICTIM OF A SCAM. *TR

NHTSA ID

10504616

Incident

Jan 3, 2013

Mileage

198,649 mi

NOTICED FUEL LEAK WHEN RETURNED AFTER PARKING AT SLANTED PARKING SPACE. INSPECTION BY LICENSED MECHANIC IN COLUMBUS, OHIO CONFIRMED FUEL TANK LEAK. REMOVED TANK FOR FURTHER INVESTIGATION AND FOUND CRACK. REPAIRED BY SAME MECHANIC. TOTAL COST CLOSE TO $300.00. NOW NO GASOLINE LEAK. *TR

NHTSA ID

10476963

Incident

Sep 4, 2012

Mileage

170,000 mi

For 1999-2003 Windstar vehicles Safety Recall 11S16 has been issued for vehicles that are operated in high corrosion areas for an extended period, where a front subframe lower control arm (LCA) rear attaching flange or rear body mount could separate from the vehicle subframe. Separation of one LCA attachment or both rear body mounts may result in a loss of vehicle directional control, increasing the risk of a crash.

GROAN/BUZZ/VIBRATION WHEN THE GEAR SELECTOR IS IN PARK WITH THE VEHICLE PARKED ON AN INCLINE. *TT THIS BULLETIN UPDATES PREVIOUS BULLETIN 17358, DATED 11/01/2003 TO INCLUDE 2005 MODELS. *TT

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT

SLIGHT AMOUNT OF FLUID RESIDUE ON THE OUTSIDE OF THE REAR WHEEL CYLINDER DUST BOOT ON VEHICLES WITH REAR DRUM BRAKES. *TT

TORQUE CONVERTER CLUTCH NOT ENGAGING WHEN COMMANDED AND/OR DIAGNOSTIC TROUBLE CODES P0741 OR P1744 STORED IN MEMORY. MODELS FROM 1996 TO 2003. *TT