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1995 Ford WINDSTAR Electrical System Wiring Front Underhood Problems, Complaints and Defects

Issue ID	365545
Internal NHTSA #	763020
Manufacurer	Ford Motor Company
Brand	FORD
Model	WINDSTAR
Model Year	1995
File date	24/12/01
Component	ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
Product type code	VEHICLE
Description of the problem	I was driving from wisconsin to pennsylvania at night. In ohio, i noticed a significant loss of power, and "whooshing" noise from under chassis, gradually getting worse over a couple of hours. At that point, the check engine light also came on. After arriving in pittsburgh (and after christmas holiday) i took the car to a muffler shop. As i expected, one of the catalytic convertors was clogged. On diagnosing the pcm fault codes, they discovered that the rubber hoses connecting to the dpfe (differential pressure feedback egr) sensor was nearly completely melted away (because of the increased exhaust backpressure from the cat failure???). I was preparing the car for another long-distance trip on 6/10/02 when i discovered that the plastic air intake plenum and the wiring harness in that area were damaged by heat, as well. The area of damage is right in the area of the metal tubes coming from the exhaust system that the rubber hoses to the dpfe sensor connect to. About 8 of the wires had their insulation completely burned through (about 1" in length). Many of the rest of the wires had embrittled insulation, or the insulation was melted together (there seem to be about 50 conductors in the wiring harness at that location). I'm really quite surprised that no fuses blew, since the bare wires were all adjacent to eachother (on the back side of the wire bundle, out of sight if you're not looking closely). I hadn't detected any electrical failures at the time, or during the intervening 6 months, but this was clearly a fire hazard. I have some reasonably clear digital photographs of the damaged wires (taken while i repaired the insulation on all of the conductors with vinyl electrical tape). I'll be happy to email them to you if you're interested.*ak
Vehicle Mileage at Failure
Number of Occurences	1
Source of the issue	NHTSA WEB SITE
City and State	BLUE MOUNDS, WI
VIN pattern	2FMDA5141SBXXXXXX
Was vehicle invloved in a crash?
Was vehicle involved in a fire?	N
Was incedent reported to police?	N
Was medical attention required?
Was part original equipment?
No. of injured persons	0
No. of fatalities	0
Date of purchase	01/01/96
Was original owner?	N
Anti-lock brakes	Y
Cruise control	Y
Number of cylinders
Drive train type	FWD
Transmission type
Vehicle speed	65
DoT tire identifier
Tire size
Location of tire code
Type of tire failure code
Was defective tire repaired?
Date of manufacture
Type of child seat code
Type of restraint
Dealer's name
Dealer's telephone number
Dealer's city
Dealer's state code
Dealer's ZIP code

What is Recall?
A recall is when a product is removed from the market or a correction is made to the product because it is either defective or potentially harmful.
What is Failure?
Failure is the state or condition of not meeting a desirable or intended objective, and may be viewed as the opposite of success. Product failure ranges from failure to sell the product to fracture of the product, in the worst cases leading to personal injury, the province of forensic engineering.
What is Defect?
Non-conformance of a car component with the specified requirements, or non-fulfillment of user expectations, including the safety aspects.

Last decoded VIN:

WF04XXGCC4HM66340 KMHJN81VP5U109844 WF0SXXGBWS7U28283 ZFA3120000J004586 5TFDV58138X079678 2T1BU4EE5BC736899 WF0EXXSK7RX007814 1J4GR48K75C706982 1GTHK29UX3E251677 WVWZZZCDZNW303330 WAUHFCFC3DN077150 3HTGSSNTXHN751572

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1995 Ford WINDSTAR Electrical System Wiring Front Underhood Problems, Complaints and Defects, Recalls and Failures

1995 Ford WINDSTAR Electrical System Wiring Front Underhood Problems, Complaints and Defects

What is Recall?

What is Failure?

What is Defect?