2003 Ford Escape brakes problems

What is wrong

On certain sport utility vehicles equipped with antilock brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short.

Risk

An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated.

Remedy

Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on april 23, 2007. Owners may contact ford at 1‑800‑392‑3673.

Recall number 07V156000 · Recall details

Ford and Mazda recalled model year (MY) 2001 through 2004 Ford Escape (07V‑156) and Mazda Tribute (07V‑157) vehicles due to non-crash fires or non-fire thermal events originating in the engine compartment at or near the ABS control module.Approximately 545,700 vehicles were subject to the initial safety recalls and approximately 424,700 vehicles were serviced under those campaigns. The campaigns addressed potentially damaged, missing or misplaced seals in the ABS control module wiring harness electrical connector that could allow brake fluid to enter the connector, possibly resulting in corrosion, short-circuit, melting, smoke and/or fire.Since the recall, the agency is aware of 260 subject vehicles that have reportedly experienced non-crash fires or non-fire thermal events originating at or near the ABS control module in vehicles some time after being serviced under the campaign. The post-recall repair incident rates for MY 2001 and 2002 subject vehicles are 90.9 and 126.7 (normalized per 100,000 vehicles serviced under the recall campaigns), respectively.These rates are much higher than the post-recall repair incident rate for MY 2003 and 2004 subject vehicles, which are 5.0 and 3.7 per 100K, respectively.Similarly, the post-recall repair key-off fire incident rates in the MY 2001 and 2002 subject vehicles is 54.3 per 100K, compared to 0.5 per 100K for the MY 2003 and 2004 subject vehicles.The agency is aware of 12 key-off fire incidents, all involving MY 2001 and 2002 subject vehicles, where the vehicle was parked inside a structure when the fire started.In five of those incidents, the fire spread from the vehicle to the structure itself.Ford has identified the brake master cylinder reservoir cap in certain MY 2001 and 2002 subject vehicles as a potential source for brake fluid leaks that could affect ABS module connector integrity.The reservoir caps used on the MY 2003 and 2004 subject vehicles are reportedly an improved design from those used on the earlier models.By letter dated January 4, 2012, Ford notified the agency that it would conduct another safety recall (identified by NTHSA Recall No. 12V‑005 and Ford Recall No. 11S24) of certain MY 2001 and 2002 Ford Escape vehicles to perform a more thorough remedy to address the risk of fire originating at the ABS control module.In addition to double-checking the ABS control module wiring harness electrical connector weather seal (which should have been addressed under the previous recall campaign), Ford will replace brake master cylinder reservoir caps to address the leaking cap problem and reduce the risk of brake fluid entering the subject electrical connector.Ford will also modify the electrical system such that the ABS control module is de-energized when the ignition key is switched off to further reduce the risk of an unattended vehicle fire in units that may have sustained some small loss of connector integrity that may not be evident upon visual examination.Similarly, Mazda notified the agency by letter dated January 19, 2012, that it would also conduct a safety recall (identified by NTHSA Recall No. 12V‑016 and Mazda Recall No. 6712A) of certain MY 2001 and 2002 Mazda Tribute vehicles.Ford estimates repair parts will be available beginning the second quarter of 2012. Until recall repairs are made both Ford and Mazda are advising owners of affected vehicles to reduce the safety concern by parking their vehicles outdoors away from structures to prevent a potential fire from spreading.Accordingly, this investigation is closed.

EA10002

In letters dated march 30, 2007, ford motor company (ford) and mazda north american operations (mazda) notified the agency that they will conduct recalls 07v‑156 and 07v‑157, respectively, to remedy a safety defect that may result in fire in a wiring connector used in certain model year (my) 2001-2004 ford escape and mazda tribute vehicles equipped with ABS.the recall campaign prescribes an inspection of the subject components, which shall be repaired or replaced only if necessary.if the subject vehicle passes the visual inspection then the recall instructs the technician to apply electrical grease (ford part number xg-12) to the ABS module connector and verify system operation.to date, approximately 388,500 subject vehicles (71.7% of the total recall population) have been serviced under the recall campaign, the vast majority of which (373,985) passed the visual inspection and received only the electrical grease applied to the ABS module connector. The agency is aware of at least 86 unique subject vehicles that have reportedly experienced non-crash fire incidents originating in the engine compartment at or near the ABS control module some time after the vehicle was serviced under the subject recall.the manufacturer has provided some information that indicates certain vehicles were improperly serviced under the subject recall as evidenced by the factory wire tie-wrap not being removed from the wiring harness (which indicates a proper inspection could not have been performed) and by incorrect grease being applied, incorrect amounts of grease, and even instances where no grease was applied to the ABS module connector.also, there remain some questions regarding the severity of the reported fire incidents.the manufacturer contends that most reported fires were actually non-fire thermal events with damage limited to the subject components and that most vehicles are repaired and returned to service.however, the trend appears to be ongoing with 5 reported incidents having occurred in the past 6 months.accordingly, this recall query has been upgraded to an engineering analysis to further assess the effectiveness of the recall remedy.

RQ09002

The office of defects investigation (odi) received a defect petition dated march 5, 2009 alleging that the petitioner never received the recall remedy for 07v‑156 and that, as a result, the petitioner's my2003 ford escape caught fire at the ABS control module.in response to odi follow-up, the manufacturer verified that the petitioner's vehicle had in fact received service related to safety recall 07v156 - a fact later corroborated by the petitioner.circumstances of the fire experienced in the petitioner's remedied vehicle indicate that the remedy was ineffective.additional review by odi identified an additional 6 similar (alleged to have originated in the engine compartment at or near the ABS control module ) non-crash fire incidents in subject vehicles known to have received the recall remedy.accordingly, a recall query (rq09-002) has been opened to assess the effectiveness of the recall remedy.

DP09003

In letters dated march 30, 2007, ford and mazda notified the federal safety agency that they will conduct safety recalls to remedy a safety defect that may result in fire in a wiring connector used in certain model year (my) 2001-2004 ford escape and mazda tribute sport utility vehicles equipped with ABS.recall 07v‑156 involves approximately 446,450 my 2001-2004 escape vehicles manufactured from october 22, 1999 through january 23, 2004.recall 07v‑157 involves approximately 95,300 my 2001-2004 tribute vehicles manufactured from april 17, 2000 through december 19, 2003. According to the manufacturers, the electrical wiring connectors to the ABS electronic control module were manufactured with wire seals missing or improperly installed in some wiring harnesses used in the recall populations.this may allow environmental contaminants such as water or brake fluid to enter the ABS electrical connector interface and cause corrosion of the electrical terminals.such corrosion may result in an illuminated ABS telltale, an open circuit, and/or an engine compartment fire originating at the electrical connector.to remedy the defect, the manufacturers will inspect the connectors for seal integrity.if a seal integrity issue is identified the vehicle will be repaired as necessary.all vehicles will have dielectric grease applied to the connectors to further reduce the possibility of contaminants entering the electrical connectors. To date, odi is aware of 120 non-crash related fire incidents alleged to have originated in the engine compartment at or near the ABS electronic control module in the subject vehicles, which represent approximately 80 percent of the recall population.of the 120 alleged fires, 6 are alleged to have occurred when the vehicle was parked inside a garage structure.in 4 incidents, complainants alleged the structure or adjoining structure(s) suffered smoke damage, while in 2 incidents, the alleged fires caused more extensive damage totaling approximately $50,000 each.there are no known injuries or fatalities related to the alleged defect.based on the ford and mazda recalls, this investigation is closed.

PE06048