1997 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.

THE SUBJECT VEHICLES RANGE IN AGE FROM 4?7 YEARS IN SERVICE, WITH AVERAGE MILEAGES ESTIMATED TO RANGE FROM 50 TO 100 THOUSAND MILES.AT THESE MILEAGES, THE SUBJECT WHEELS ARE LIKELY TO HAVE BEEN REMOVED AND REINSTALLED MULTIPLE TIMES FOR VARIOUS SERVICE PROCEDURES.ODI IS CONCERNED ABOUT THE HIGH WHEEL SEPARATION RATES IN THE MY 1997-98 WINDSTAR VEHICLES EQUIPPED WITH ALUMINUM ALLOY WHEELS.HOWEVER, ANALYSIS OF FAILURE DATA INDICATES THAT MOST OF THE INCIDENTS IN THAT POPULATION OF VEHICLES OCCUR AFTER THE VEHICLES HAD ACCUMULATED 30 THOUSAND MILES OF SERVICE. THE FACTORS THAT INCREASE THE RISK THAT INADEQUATE CLAMP LOADS MAY BE ACHIEVED DURING SERVICE-RELATED WHEEL INSTALLATION ARE NOT UNIQUE TO THE SUBJECT VEHICLES.TESTING CONDUCTED BY FORD AND VRTC INDICATE THAT THE MY 1998 WINDSTAR ALUMINUM WHEEL FASTENING SYSTEM PERFORMS SIMILAR TO THE WHEEL FASTENING SYSTEMS ON PEER MINIVANS.NO DESIGN OR MANUFACTURING DEFECTS WERE IDENTIFIED IN THE WHEEL FASTENING SYSTEMS OF THE SUBJECT VEHICLES. FORD WILL SEND A MAILING TO OWNERS OF WINDSTAR VEHICLES WITH ALUMINUM WHEELS THAT HAVE HIGH WHEEL SEPARATION RATES THAT REVIEWS THE APPROPRIATE WHEEL FASTENING PROCEDURES AND STATES THAT THE WHEEL NUTS SHOULD BE TIGHTENED TO THE NOMINAL TORQUE, 100 FT-LBS (136 NM), AND RE-TIGHTENED TO THE SAME TORQUE AFTER 500 MILES.FORD?S LETTER ALSO STATES THAT IT IS ?A GOOD PRACTICE TO BE SURE THAT BEFORE INSTALLING THE WHEEL THE ALUMINUM WHEEL MOUNTING SURFACE, WHEEL LUG NUT AREA, AND THE MOUNTING FLANGE ARE FREE FROM DIRT, DEBRIS, AND LOOSE RUST TO ENSURE THE WHEEL IS SEATED CORRECTLY AND THE WHEEL LUG NUTS REMAIN FULLY TIGHTENED.? ODI WILL CONTINUE TO MONITOR THE INCIDENCE OF WHEEL FASTENER FAILURES IN THE SUBJECT VEHICLE POPULATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

There is no summary currently available

TL* THE CONTACT OWNS 1997 FORD WINDSTAR. THE CONTACT STATED WHILE TRAVELING 65 MPH THE REAR AXLE BEAM BECAME FRACTURED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. A PRIVATE MECHANIC STATED THAT THE REAR AXLE BEAM NEEDED TO BE REPLACED. THERE WERE NO REPAIRS MADE ON THE VEHICLE. THE FAILURE MILEAGE WAS 140,000 AND THE CURRENT MILEAGE WAS 140,000.

NHTSA ID

10588611

Incident

May 8, 2014

Mileage

140,000 mi

TL* THE CONTACT OWNS A 1997 FORD WINDSTAR. THE CONTACT STATED THAT AFTER HAVING THE VEHICLE INSPECTED, HE WAS NOTIFIED THAT THE VEHICLE FAILED TO PASS THE STATE INSPECTION DUE TO THE SUB FRAME BEING COMPLETELY CORRODED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE SUB-FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ID

10471878

Incident

Aug 22, 2011

Mileage

13,000 mi

TL* THE CONTACT OWNS A 1997 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE TRACK BAR DETACHED FROM THE VEHICLE. THE CONTACT STATED THAT THE VEHICLE BEGAN TO WOBBLE EXCESSIVELY. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE AND ADVISED THE CONTACT NOT TO DRIVE THE VEHICLE. THE FAILURE MILEAGE WAS 90,000. UPDATED 09/21/12*LJ THE VEHICLE WAS REPAIRED BY A LOCAL MECHANIC AT THE OWNER'S EXPENSE. THE DEALER WAS MADE AWARE OF FAILURES. UPDATED 09/26/2012 *JS

NHTSA ID

10470168

Incident

Aug 10, 2012

Mileage

90,000 mi

I PURCHASED A 1997 FORD WINDSTAR AND FROM WHAT I UNDERSTAND IS THAT THERE WAS A RECALL ON THE COIL SPRINGS/SUSPENSION. (RECALL#01I00700) < I BELIEVE THIS IS THE RECALL #. LONG STORY SHORT MY FRONT TIRES ARE FLAT DOUE TO THE COIL SPRINGS. NONE OF THE DEALERS I TOOK IT TO ARE WILLING TO FIX THIS. THEY SAY IT IS NOT COVERED UNDER ANY RECALL... PLEASE HELP ME BETTER UNDERSTAND WHY FORD WONT FIX THIS DEFECT. *TR

NHTSA ID

10436452

Incident

Apr 13, 2011

MY WINDSTAR GL WOULDN'T START. I REPLACED THE RANGE SELECTOR SWITCH. WHEN I RESTARTED THE VEHICLE I FORGOT THE RECONNECT THE BRAKE PRESSURE SENSOR WIRING CONNECTOR AND THE ABS LIGHT CAME ON. I TRIED TO GET THE CODE CLEARED BUT NO-ONE COULD ACCESS THE CODE. I TOOK THE VAN TO THE DEALER FOR A RECALL NOTICE ON THE SPEED CONTROL SYSTEM AND HAD THEM LOOK INTO WHY THE ABS LIGHT WAS ON. I WAS TOLD THE ABS MODULE HAD QUIT AND NEEDED REPLACED. THE MODULE IS $1500.00 AND $300.00 TO INSTALL. THAT'S MORE THAN THE VAN IS WORTH. I SEARCHED ONLINE AND FOUND OUT MANY OTHER WINDSTAR OWNERS ARE HAVING THE SAME PROBLEMS. THE CRUISE CONTROL SYSTEM HAS ALSO QUIT AND THE DEALER REP. TELLS ME THAT THE CRUISE CONTROL ALSO GOES THROUGH THIS MODULE. WITH THE POSSIBILITY OF FIRE IT SEEMS RATHER IRRESPONSIBLE FOR FORD TO DO NOTHING MORE THAN INSTALL A FUSIBLE LINK AS A SAFETY MEASURE. I AM LOOKING INTO BUYING A USED MODULE TO REPAIR THE CRUISE AND ABS. THE FAILURE IS TOTAL. NEITHER THE CRUISE CONTROL OR THE ABS SYSTEM WORKS AT THIS TIME. *TR

NHTSA ID

10349332

Incident

Nov 10, 2009

Mileage

90,000 mi

I HAD MY 97 WINDSTAR FAN FIXED DUE TO RECALL # 09S09:SPEED CONTROL SYSTEM MODIFICATION. EVER SINCE THEN THE ABS AND PARKING LIGHTS HAVE BEEN COMING ON. WE HAVE HAD THE CODES RESET, BUT THEY KEEP APPEARING. I HAVE ALSO CALLED THE FORD DEALER WHERE THE REPAIR WAS DONE, BUT THEY SAY IT IS NOT COVERED IN THE RECALL TO CHECK THE SCDS, OR THAT IF IT WASN'T LEAKING THEN, THEY DID NOT HAVE TO REPLACE THAT PART. I AM VERY FRUSTRATED. *TR

NHTSA ID

10334277

Incident

Jan 19, 2010

I TURNED THE AIR CONDITIONING ON IN THE VAN AND AFTER ABOUT 10 MINUTES, TURNED IT TO THE 'MAX AC' POSITION. THE HOOD STARTED STEAMING SO I TURNED THE AIR COMPLETELY OFF. AFTER LESS THAN A MINUTE, I NOTICED THE HOOD WAS SMOKING SO I PULLED TO THE SIDE OF THE ROAD IMMEDIATELY. I TURNED THE CAR OFF AND EXITED THE VAN AND SAW THAT THE PASSENGER SIDE OF THE HOOD WAS ON FIRE. I RAN TO THE PASSENGER SIDE AND OPENED THE SLIDING DOOR, AND GOT MY 18 MONTH OLD AND 4 YEAR OLD OUT OF THE VEHICLE. AFTER WE WERE ALL A SAFE DISTANCE AWAY I SAW THAT MOST OF THE HOOD OF THE VAN WAS IN FLAMES. BY THE TIME THE FIRE DEPARTMENT ARRIVED ABOUT 5 MINUTES LATER, THE ENTIRE HOOD WAS ON FIRE WITH A LOT OF BLACK SMOKE. THE ENTIRE ENGINE COMPARTMENT LOOKS CHARRED AND PARTIALLY MELTED. THE VEHICLE IS BEYOND REPAIR. I'M THANKFUL MY CHILDREN ARE SAFE BUT I AM VERY CONCERNED ABOUT THE SAFETY (FAILURE) OF THIS VEHICLE. *TR

NHTSA ID

10334181

Incident

May 28, 2010

Mileage

135,000 mi

OUR 1997 FORD WINDSTAR MINIVAN THAT IS CURRENTLY SUBJECTED TO THE RECALL FOR THE FAULTY CRUISE CONTROL SWITCH BURNED TO THE GROUND ON FEB 21, 2007 AS THE RESULT FROM A FIRE THAT STARTED IN THE ENGINE AREA. *TR

NHTSA ID

10289494

Incident

Feb 21, 2007

Mileage

220,000 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.

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

LITERATURE PROGRAM 04L23. CUSTOMER MAINTENANCE REMINDER - ALUMINUM WHEEL LUG NUT TORQUE. *TT

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

MALFUNCTION INDICATOR LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0442, P0455, P0456, P0457 OR P1442 OR A CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FOR THE EVAPORATIVE EMISSION SYSTEM. *TT

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