1995 Ford Windstar brakes problems

What is wrong

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.

Risk

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.

Recall number 02V101000 · Recall details

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 the federal safety agency that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.

RQ04003

There is no summary currently available

PE98056

There is no summary currently available

EA96026

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.

PE96042