EA08-021

1995-2003 Ford Windstar

Engine Compartment Fires

Fact Sheet
1
 Contents
• Summary
• Alleged Failure
• Background
• Peer Vehicles
• Previous Engine Compartment Fire Actions
• Peer Complaint Comparison
• Complainant Evidence
• VRTC Testing

2
 Summary
EA Opened: 17-Sep-08
Alleged Defect:
Engine Compartment Fires
Subject Vehicles:
1995-2003 Ford Windstar
Population: 1,643,432
Complaints:
ODI – 185
Ford – 325 (Cat A or S)
Total – 510
Warranty Claims:
Ford – 146 (Cat A or S)

3
 Alleged Failure

• The Speed Control Deactivations Switch (SCDS) develops an

internal leak that allows brake fluid to escape the brake system.
• The brake fluid that leaks past the seals in the SCDS can
potentially result in a vehicle fire in two separate ways
– The brake fluid leak within the SCDS results in a short circuit
internal to the SCDS. The SCDS then catches fire and the fire
spreads to the engine compartment of the vehicle. This scenario
can lead to a fire while the vehicle is running or to a fire that starts
while the vehicle is running and then spreads after the vehicle is
parked.
– The brake fluid that leaks past the SCDS migrates through the
vehicle wire harness to the ABS module. Once the brake fluid
reaches the ABS module, a fire can start at any time as the ABS
module has power to it at all times. The fire can then spread from
the ABS module to the underbody of the vehicle.

4
 Kapton Motion (“Oil Can”)

• Kapton Seal Position Starting From Full Pressure Moving To

Vacuum

5
 New SCDS Kapton

• Kapton From New SCDS Off Master Cylinder Replacement Part Ordered for
MY2000 F150

• Seal 1 • Seal 2 • Seal 3

6
 Background
• ODI has conducted 3 investigations involving Ford vehicles manufactured with
the Texas Instruments (TI) Speed Control Deactivation Switch (SCDS).
• These 3 investigations resulted in 7 recalls of over 12 million vehicles
• Ford has indicated that they manufactured approximately 16 million vehicles that
included the TI SCDS as original equipment.
• The vehicles that Ford has recalled to date have all had SCDS that were
powered at all times (PAT) regardless of key position.
• Ford did not originally recall the Windstar vehicles because they had a low rate
of fire and they were not PAT.
• ODI has received 510 complaints on Windstar vehicles indicating a potential
failure of the SCDS. Of these complaints 166 mention fire, smoke, or burn.
Of the 166 Windstar complaints that mention fire, smoke, or burn 3 resulted in
structure fires.
• 12 of the fire complaints involved the ABS module (post 1998 MY). The ABS
module is powered at all times and these fires can occur while the vehicle is
parked.
• During the previous investigations it was discovered that the SCDS could wear
out and leak as a result of the internal Kapton seals “oil canning”. This
phenomenon was discovered to occur as a result of vacuum pressures
developing on the brake system when the brake pedal is released.

7
 NHTSA Go, No-Go Complaint Analysis
SCDS Caused Fire
• Yes: The following criteria must be met.
(1)Eye witness to fire directly on the SCDS after opening the hood.
Or;
(2) The fire originated in the area where the speed control deactivation switch is located (left-rear corner
of the engine compartment, at the master cylinder). This origin point would be evidenced by burn
patterns seen in photographs or by eye witness account.
And (3) or (4);
(3) There was evidence of speed control deactivation switch failure prior to the fire (e.g., inoperable
speed control, speed control deactivation switch fuse open – sometimes repeatedly, difficulty shifting out
of PARK, evidence of brake fluid leakage from the switch)
(4) Evidence of speed control switch failure discovered during post-fire forensic examination.
• Maybe: The following criteria must be met.
(1) The fire originated in the area where the speed control deactivation switch is located (left-rear corner
of the engine compartment, at the master cylinder). This origin point would be evidenced by burn
patterns seen in photographs or by eye witness account.
Or;
(2) There was evidence of speed control deactivation switch failure prior to the fire (e.g., inoperable
speed control, speed control deactivation switch fuse open – sometimes repeatedly, difficulty shifting out
of PARK, evidence of brake fluid leakage from the switch, or ABS/Brake warning lights showing on the
dash)
Or,
(3) Evidence of speed control switch failure discovered during post-fire forensic examination.
• No: The following criteria must be met.
(1) The fire originated away from the master cylinder. This origin point would be evidenced by burn
patterns seen in photographs or by eye witness account.
Or;
(2) Physical evidence exists that indicate the fire did not start at the SCDS.

8
Fires
Current Go, No-Go Analysis
Failure Yes Maybe No Unknown Failure Count Rate (R/100k)
SCDS Fires 97 8 2 1 SCDS Fire 106 6.4
ABS Fires 17 2 0 0 ABS Fire 19 1.2
Propery Damage 0 1 1 2 SCDS + ABS Fires 125 7.6
Unknown Origin 60 Unk Eng Comp Fire 60 3.7
Total 114 11 3 63 Total Fires 185 11.3
SCDS Leaks 124 7.5
Non Fires Total Leaks + Fires 309 18.8
SCDS Leak 124 Population 1,643,432
Brake Fluid @ ABS 17
Brake/ABS Light On 153
Speedometer Fail 53

Fire = Yes Fire = N o

Failure SCDS Fire ABS Fire Unknown SCDS Leak Brake Fld @ ABS Brake/ABS Lights OSpeedometer Fail
Count 97 17 60 124 17 153 54
Ignition On 46 1 29 11 1
Ignition Off 12 7 16 0 0
Ignition Unk 39 9 15 113 16
ABS/Brake Light On 15 7 8 62 12
Speedometer Fail 9 5 2 34 5 37
Parked < 30 Min 1 1 7 0 0
Property Damage 0 0 2 0 0
1995 7 0 9 2 0 4 0
1996 19 0 10 2 0 3 1
1997 3 0 2 1 0 1 1
1998 3 0 21 10 2 5 1
1999 15 2 2 11 0 6 5
2000 21 0 3 31 4 17 19
2001 18 5 7 31 3 40 14
2002 8 10 3 26 5 41 10
2003 3 0 3 10 3 36 3
Note: Some vehicles had both a SCDS and 9
an ABS failure
 Peer Vehicles
(1995 – 2003 MY Mini Vans)

• 1995 – 2003 Chrysler Mini Vans

– Town & Country
– Voyager
– Caravan
– Grand Caravan
• 1995 – 2003 Honda Odyssey
• 1998 – 2003 Toyota Sienna

10
 Engine Fire Related Recalls
On Peer Vehicles
• Chrysler vans
– 95V-236 1996 MY vans (80,000) the fuel tank rollover valve can allow fuel
to pass into the vapor canister resulting in the potential for fuel leakage.
– 96V-006 1996 MY vans (40,000) in certain vehicles, the engine cylinder
head oil galley plug does not seal properly.
– 99V-216 1996 MY vans (635,469) the fuel tank rollover valve can allow fuel
to pass into the vapor canister resulting in the potential for fuel leakage.
– 00V-268 1996 - 2000 MY vans (1,163,000) 3.3l and 3.8l engines have fuel
rails with nitrole rubber o-ring seals that can degrade over time. Fuel
leakage from the underhood fuel injection fuel rail could result, increasing
the likelihood of a vehicle fire.

• Odyssey
– None

• Sienna
– None

11
 Rate (R/100K)

0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
Windsta-2001

Windsta-2002

Windsta-1997

Windsta-1996

Windsta-2003

Odyssey-1996

Windsta-2000

Windsta-1999

Odyssey-1997

Windsta-1998

Odyssey-1998

Odyssey-1999

Windsta-1995

Model - MY
Sienna -2002
(ODI Data Only)

Sienna -1999
Running and Parked Fires

Sienna -1998

Odyssey-2001

Sienna -2000
1995 - 2003 MY Mini Van Engine Compartment Fire Rates
Chrysler Vans Removed Due To Engine Fire Related Recalls

Odyssey-2003

Odyssey-2002

Odyssey-2000

Odyssey-1995

Sienna -2003

Sienna -2001
12
Mini Vans
 2003 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

12.0

10.0

8.0
T&C-2003
Caravan-2003
Rate (R/100K)

GC-2003
6.0 Voyager-2003
Odyssey-2003
Sienna-2003
Windstar-2003
4.0

2.0

0.0
0 1 2 3 4 5
YIS

13
 2002 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

16.0

14.0

12.0

10.0 T&C-2002
Caravan-2002
Rate (R/100K)

GC-2002
8.0 Voyager-2002
Odyssey-2002
Sienna-2002
6.0 Windstar-2002

4.0

2.0

0.0
0 1 2 3 4 5 6
YIS

14
 2001 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

18.0

16.0

14.0

12.0
T&C-2001
Caravan-2001
Rate (R/100K)

10.0 GC-2001
Voyager-2001
8.0 Odyssey-2001
Sienna-2001
Windstar-2001
6.0

4.0

2.0

0.0
0 1 2 3 4 5 6 7
YIS

15
 2000 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

12.0

10.0

8.0
T&C-2000
Caravan-2000
Rate (R/100K)

GC-2000
6.0 Voyager-2000
Odyssey-2000
Sienna-2000
Windstar-2000
4.0

2.0

0.0
0 1 2 3 4 5 6 7 8
YIS

16
 1999 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

10.0

9.0

8.0

7.0

T&C-1999
6.0
Caravan-1999
Rate (R/100K)

GC-1999
5.0 Voyager-1999
Odyssey-1999
4.0 Sienna-1999
Windstar-1999

3.0

2.0

1.0

0.0
0 1 2 3 4 5 6 7 8 9
YIS

17
 1998 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

25.0

20.0

T&C-1998
15.0
Caravan-1998
Rate (R/100K)

GC-1998
Voyager-1998
Odyssey-1998
10.0 Sienna-1998
Windstar-1998

5.0

0.0
0 1 2 3 4 5 6 7 8 9 10
YIS

18
 1997 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

25.0

20.0

15.0 T&C-1997
Rate (R/100K)

Caravan-1997
GC-1997
Voyager-1997
Odyssey-1997
10.0 Windstar-1997

5.0

0.0
0 1 2 3 4 5 6 7 8 9 10 11
YIS

19
 1996 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

35.0

30.0

25.0

T&C-1996
Rate (R/100K)

20.0 Caravan-1996
GC-1996
Voyager-1996
15.0 Odyssey-1996
Windstar-1996

10.0

5.0

0.0
0 1 2 3 4 5 6 7 8 9 10 11 12
YIS

20
 1995 MY Mini Vans
Cumulative Engine Fire Rate vs. YIS

6.0

5.0

4.0

T&C-1995
Rate (R/100K)

Caravan-1995
GC-1995
3.0
Voyager-1995
Odyssey-1995
Windstar-1995
2.0

1.0

0.0
0 1 2 3 4 5 6 7 8 9 10 11 12 13
YIS

21
 Previous Engine Compartment
Fire Investigations

Model Production Rate @ Close First MY Last MY InvestigatioRecall

FORD FOC US 690,045 2.0 2000 2002 EA02-014 02V-288
VOLKSWAGEN PASSAT 345,642 23.1 2000 2003 EA07-014 08V-156
FORD CONTOUR/MERCURY MYSTIQUE 262,559 3.0 1995 1995 EA00-005 00V-367
WINDSTAR Current 1,643,432 10.1 1995 2003 EA08-021
WINDSTAR At Close EA05-005 (Estimated Prod) 1,708,381 2.2 1995 2003

Peer Investigations With Engine Compartment Fire, Electrical Cause, No Fuel Leak, >250K Production, Key On/Unk

22
 Complainant Evidence

• 2002 Windstar, Bakersfield, CA, July 2008 ODI #10233254

– Leak at SCDS
– Brake fluid spreads to Neutral Safety Switch

23
 Complainant Evidence

• 2000 Windstar, Chillicothe, OH, March 2009 Ford #568300639

– Leak at SCDS
– Brake fluid spreads to Neutral Safety Switch

24
 Complainant Evidence

• 2001 Windstar, Ontario, Canada, May 2009 ODI #10269848

– Leak at SCDS
– Brake fluid spreads to Neutral Safety Switch

25
 Complainant Evidence

• 1995 Windstar, Portland, OR, July 2007 ODI #10196226

– Fire at SCDS
– Fire spread to Neutral Safety Switch
– Fire Extinguished

26
 Complainant Evidence

• 1996 Windstar, Seekonk, MA, September 2008 ODI #10248707

– Fire at SCS

27
 Complainant Evidence

• 1998 Windstar, Miami, FL, October 2008 ODI #10248843

– Fire at SCDS

28
 Complainant Evidence

• 2000 Windstar, Easley, SC, March 2007 ODI #10188784

– Fire at SCDS

29
 Complainant Evidence

• 2001 Windstar, Orlando, FL, May 2007 ODI #10189990

– Fire at SCDS
– Fire spread to structure
30
 Complainant Evidence

• 2000 Windstar, Gordonsville, VA, September 2008 ODI #10242836

– Fire at SCDS

31
 Complainant Evidence

• 2002 Windstar, Bennington, VT, September 2007 ODI #10202250

– Brake fluid leak at SCDS
– Brake fluid migrates to ABS module thru wire harness
– Fire at ABS Module
– Fire Extinguished

32
 Complainant Evidence

• 2002 Windstar, Covington, TN, December 2008 ODI #10251326

– Brake fluid leak at SCDS
– Brake fluid migrates to ABS module thru wire harness
– Fire at ABS Module
– Fire Extinguished

33
 Complainant Evidence

• 2001 Windstar, Gloucester, MA, June 2008 Ford #610101638

– Brake fluid leak at SCDS
– Brake fluid migrates to ABS module thru wire harness
– Fire at ABS Module
– Fire Extinguished

34
 Complainant Evidence

• 2002 Windstar, Denver, CO, January 2009 ODI #10254284

– Brake fluid leak at SCDS
– Brake fluid migrates to ABS module thru wire harness
– Fire at ABS Module
– Fire Extinguished

35
 VRTC Testing
• VTRC was contacted to conduct live burn tests on the subject vehicles
to determine
– How a fire might spread from the SCDS if it were to catch fire
– How a fire might spread from the ABS module if it were to catch fire
– The burn patterns that would result from a fire caused by a burning SCDS
– The burn patterns that would result from a fire caused by a burning ABS
• Three vehicles were found and used for testing
– Vehicle 1 (Blue Van):
• 2000 FORD WINDSTAR LX
• EXTENDED SPORT VAN 3.8L V6 SFI
– Vehicle 2 (Green Van):
• 2002 FORD WINDSTAR LX
• EXTENDED SPORT VAN 3.8L V6 SFI OHV
– Vehicle 3 (White Van):
• 1999 FORD WINDSTAR SE
• EXTENDED SPORT VAN 3.8L V6 SFI

36
 Live Burn Testing
• SCDS Fire Spread Test 1

37
 Live Burn Testing
• SCDS Fire Spread Test 2

• Under Hood Fire Footage (click)

• Exterior Fire Footage (click)
38
 Live Burn Testing
• ABS Module Fire Spread Test

• Under Body Fire Footage (click)

39
 VRTC Testing
Findings and Conclusions
• A SCDS that is on fire and drops down to the engine allows for the fire
to spread to the engine compartment and the remainder of the vehicle.
This fire spread can occur whether the engine is running or not.

• If brake fluid in the ABS module does catch on fire, the fire can spread
to the underbody of the vehicle and potentially the engine compartment
of the vehicle.

• Burn patterns generated on the test vehicles support allegations on

complainant vehicles that SCDS or brake fluid leaking from the SCDS
to the ABS module caused a fire.

40
 Rate (R/100K)

0
5
10
15
20
25
30
35

2000-F150
1996-BRONCO
2000-EXPEDITION
2000-EXCURSION
1997-F150
92-93-Panther Recall Veh
1996-F150
1998-EXPEDITION
1997-EXPEDITION
1998-EXPLORER
2001-F150
1996-ECONOLINE
2001-EXCURSION
1998-NAVIGATOR
1998-F150
1999-EXPEDITION
2001-EXPEDITION
2002-EXCURSION
2000-NAVIGATOR
1999-NAVIGATOR
2002-EXPEDITION
1999-F150
1996-WINDSTAR (Not PAT)
1999-WINDSTAR (Not PAT)
2000-EXPLORER
EA02-025 Subject Veh.
ODI Data Only

1995 Ram 1500

Vehicles
1998-RANGER
Ford Vehicles W/ TI SCDS

2002-EXPLORER (Not PAT)

2000-WINDSTAR (Not PAT)
1996-EXPLORER (Not PAT)
2000 Ram 1500
2001-EXPLORER
1997 RANGER (Not PAT)
2001 Ram 1500
1996-RANGER (Not PAT)
2000-RANGER
(Recalled As Of 8-19-05, Non-Recalled As Of 11/4/05, "Good VINs" Only)

2000-ECONOLINE
1997-ECONOLINE
2002-F150
1998 Ram 1500
1999-EXPLORER
1999-RANGER
GM/DC Peers W CC

1998-WINDSTAR (Not PAT)

1997-EXPLORER (Not PAT)
2001-WINDSTAR (Not PAT)
Ford Vehicles W CC(Recalled)

Ford Vehicles W CC( Not PAT)

1996 Ram 1500

1999 Ram 1500
Ford Vehicles W CC(Not Recalled)

2000 Silverado
1997 Ram 1500
1999 Silverado
SCDS Dendrite Growth

42
SCDS Dendrite Growth

43
 Ford Complaint Data
(S & A Categories Only)

Calendar Year
MY 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
1995 3 4 2 1 2 1 0 0 1 4 3 0 0
1996 - 2 1 0 0 2 1 6 5 14 3 8 3
1997 - - 0 0 0 1 1 3 1 2 4 2 5
1998 - - - 0 0 1 0 2 1 3 13 11 7
1999 - - - - 0 0 1 3 7 13 13 11 4
2000 - - - - - 1 2 3 13 15 27 23 17
2001 - - - - - - 0 1 2 16 24 26 24
2002 - - - - - - - 1 2 5 13 19 19
2003 - - - - - - - - 1 1 0 3 3

44
 Ford Windstar
Polk Registrations vs. Years In Service

350000

300000

250000
1995
1996
Polk Registrations

1997
200000
1998
1999
2000
150000
2001
2002
2003
100000

50000

0
0 1 2 3 4 5 6 7 8 9 10 11 12
YIS

45
 Ford Engine Fire Complaints
YIS vs Complaint Rate
1995 MY Windstar

14

12

10
Rate (R/100K)

8
1995
1995 Polk
6

0
1 2 3 4 5 6 7 8 9 10 11 12 13
YIS
46
 Ford Engine Fire Complaints
YIS vs Complaint Rate
1996 MY Windstar

35

30

25
Rate (R/100K)

20
1996
1996 Polk
15

10

0
1 2 3 4 5 6 7 8 9 10 11 12
YIS

47
 Ford Engine Fire Complaints
YIS vs Complaint Rate
1997 MY Windstar

70

60

50
Rate (R/100K)

40
1997
1997 Polk
30

20

10

0
1 2 3 4 5 6 7 8 9 10 11
YIS

48
 Ford Engine Fire Complaints
YIS vs Complaint Rate
1998 MY Windstar

14

12

10
Rate (R/100K)

8
1998
1998 Polk
6

0
1 2 3 4 5 6 7 8 9 10
YIS

49
 Ford Engine Fire Complaints
YIS vs Complaint Rate
1999 MY Windstar

35

30

25
Rate (R/100K)

20
1999
1999 Polk
15

10

0
1 2 3 4 5 6 7 8 9
YIS

50
 Ford Engine Fire Complaints
YIS vs Complaint Rate
2000 MY Windstar

50

45

40

35

30
Rate (R/100K)

2000
25
2000 Polk

20

15

10

0
1 2 3 4 5 6 7 8
YIS

51
 Ford Engine Fire Complaints
YIS vs Complaint Rate
2001 MY Windstar

60

50

40
Rate (R/100K)

2001
30
2001 Polk

20

10

0
1 2 3 4 5 6 7
YIS

52
 Ford Engine Fire Complaints
YIS vs Complaint Rate
2002 MY Windstar

45

40

35

30
Rate (R/100K)

25
2002
2002 Polk
20

15

10

0
1 2 3 4 5 6
YIS

53
 Ford Engine Fire Complaints
YIS vs Complaint Rate
All MY Windstar Polk Registration

70

60

50
1995
1996
Rate (R/100K)

40 1997
1998
1999
30 2000
2001
2002
20

10

0
1 2 3 4 5 6 7 8 9 10 11 12
YIS
54