Ford document: Millions of vehicles have fire risk part
#1
06-16-2005
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Ford document: Millions of vehicles have fire risk part
http://www.cnn.com/2005/US/06/16/for...les/index.html
KISSIMMEE, Florida (CNN) -- Early this year, Laura Hernandez nudged her husband, Nestor Oyola, as he slept in their Kissimmee home and asked him to put the Ford Expedition he had bought her the day before into the garage.
She did not want to risk leaving it on the street, where it might be vandalized.
"That was my dream, to have a Ford Expedition," she recalled to CNN about the $22,000 Eddie Bauer 2001 model SUV -- green with gold trim and leather seats.
Oyola moved the Expedition and they went to sleep.
After years of sharing a single car, the couple -- who moved five years ago to the United States from Puerto Rico -- were finally living the American dream: They owned two vehicles and their home.
At 5 the next morning, half an hour after her husband had driven his SUV to work, Hernandez was awakened by barking from Chakuil, their Chihuahua mix.
"He saved our lives," said Hernandez, who smelled smoke and roused her 15-year-old daughter, Rotsenmary.
They had time to grab only the dog and their pet birds before flames spread from the garage and engulfed the house.
Rotsenmary suffered a second-degree burn to her left leg; the charred remains of their 6-month-old cat -- Beethoven -- were found in a corner; the vehicle, the house and its contents were a total loss.
A fire investigator, hired by their auto insurance company, said the blaze was caused by a cruise-control deactivation switch in the SU
V -- a type of switch that Ford installed in millions of its vehicles from 1992 until 2003.
An Iowa family is suing Ford over the switch, claiming it was the likely cause of a fire in the family's 1996 F-150 parked in an attached garage that spread to their house. A 74-year-old woman died in the fire and the house was destroyed. Ford, however, says the fire did not originate in the F-150. (Full story)
Several fire investigators hired by major insurance companies and auto engineers consulted by CNN say the switch is causing some Ford vehicles to ignite.
Expanded investigation
The $20.57 switch shuts off the cruise control when the driver firmly steps on the brakes. The switch is located under the hood of the vehicle and is attached to the brake master cylinder on one end and wired to the cruise control on the other.
On most of its models, Ford designed the switch to be powered -- or "hot" -- at all times, even when the vehicle is off and the key is removed from the ignition.
Inside the switch, a thin film barrier separates brake fluid from the switch's electrical components. Investigators say fires can occur when the film cracks and brake fluid from the master cylinder seeps into the electrical side of the switch.
Ford has already recalled more than 1 million vehicles in two separate recalls to replace the switch.
The first recall was in May 1999, affecting 279,000 Crown Victorias, Grand Marquises and Town Cars for model years 1992 and 1993. The second, issued in January 2005, affected 792,000 vehicles, including model year 2001 F-Series SuperCrews and 2000 Expeditions, Navigators and F-150 pickups.
But a Ford document obtained by CNN shows the same or similar switch was installed in a total of 16 million vehicles, far beyond what was recalled. Those vehicles include:
# Mark VII/VIII from 1994-1998
# Taurus/Sable and Taurus SHO 2.3 L 1993-1995
# Econoline 1992-2003
# F-Series 1993-2003
# Windstar 1994-2003
# Explorer without IVD 1995-2003
# Explorer Sport/Sport Trac 2002-2003
# Expedition 1997-2003
# Ranger 1995-2003
In March, the National Highway Traffic Safety Administration opened an expanded investigation into more than 3.7 million of the vehicles.
NHTSA says it has received 559 complaints of spontaneous fires, 253 of them in unrecalled models, and its latest investigation includes the 1995 model years of the F-150, Expedition and Lincoln Navigator vehicles.
Ford says it has initiated its own investigation and is cooperating with the NHTSA probe.
"We have identified specific populations of vehicles in which the speed-control deactivation switches have had increasing rates of failures and fires," said Ford spokeswoman Kristen Kinley in a written response to questions submitted by CNN.
"When we have seen the fire reports increasing, we have recalled those vehicles and replaced those switches. Ford has used the basic switch design in a large number of vehicles and the risk of fire related to the switch is much different in those certain populations that we have recalled."
She added, "It is important to understand that all speed control systems are not identical in Ford vehicles. ... In those populations with an increasing fire report rate, we stopped using the switch through the recall process. ... The switch has performed well in many models for many years."
In another statement to CNN, Kinley said "we have been asked why we have not expanded the recall. The last thing we want to do is make an important safety decision on incorrect or incomplete information."
Kinley also said, "We have not determined at this time that there is a defect with the switch, but for reasons we still do not understand the switch is failing ... and we are trying to understand why."
Ford no longer uses switch
But, in a recall notice to owners of 2000 F-150s, Expeditions, Navigators and 2001 F-150 SuperCrews, the company seemed less equivocal about the switch. The "switch may overheat, smoke or burn which could result in an underhood fire," it said. "This condition may occur either when the vehicle is parked or when it is being operated, even if the speed control is not in use."
The company stopped using the switch altogether as of the 2004 year model, and is now using a new design.
Meanwhile, the Oyola-Hernandez family has hired a lawyer to reach a financial settlement with Ford but have not filed a lawsuit against the company.
The company says it has not yet investigated their auto insurance claim, but notes that the insurance industry reports about 100,000 noncollision fires per year involving nearly all makes and models sold.
"Simply because we have allegations of fire doesn't mean they are necessarily linked to the speed-control deactivation switch," Kinley said.
The charred remains of their house were recently demolished. But, the family has not been able to rebuild.
After the fire, they moved in with Hernandez's mother, who lives nearby. Since then, after reinstating their home insurance, they have moved into a rented house. Their insurance company sent them $120,000 but rebuilding their home is estimated to cost $185,000. They are hoping Ford will reimburse them for the difference.
They are, once again, a one-car family. This one also is a Ford -- a 1997 Explorer -- and it, too, contains the suspect switch, which has not been recalled. The family parks it on the street instead of the garage.
CNN Investigative Producer Pia Malbran contributed to this story
KISSIMMEE, Florida (CNN) -- Early this year, Laura Hernandez nudged her husband, Nestor Oyola, as he slept in their Kissimmee home and asked him to put the Ford Expedition he had bought her the day before into the garage.
She did not want to risk leaving it on the street, where it might be vandalized.
"That was my dream, to have a Ford Expedition," she recalled to CNN about the $22,000 Eddie Bauer 2001 model SUV -- green with gold trim and leather seats.
Oyola moved the Expedition and they went to sleep.
After years of sharing a single car, the couple -- who moved five years ago to the United States from Puerto Rico -- were finally living the American dream: They owned two vehicles and their home.
At 5 the next morning, half an hour after her husband had driven his SUV to work, Hernandez was awakened by barking from Chakuil, their Chihuahua mix.
"He saved our lives," said Hernandez, who smelled smoke and roused her 15-year-old daughter, Rotsenmary.
They had time to grab only the dog and their pet birds before flames spread from the garage and engulfed the house.
Rotsenmary suffered a second-degree burn to her left leg; the charred remains of their 6-month-old cat -- Beethoven -- were found in a corner; the vehicle, the house and its contents were a total loss.
A fire investigator, hired by their auto insurance company, said the blaze was caused by a cruise-control deactivation switch in the SU
V -- a type of switch that Ford installed in millions of its vehicles from 1992 until 2003.
An Iowa family is suing Ford over the switch, claiming it was the likely cause of a fire in the family's 1996 F-150 parked in an attached garage that spread to their house. A 74-year-old woman died in the fire and the house was destroyed. Ford, however, says the fire did not originate in the F-150. (Full story)
Several fire investigators hired by major insurance companies and auto engineers consulted by CNN say the switch is causing some Ford vehicles to ignite.
Expanded investigation
The $20.57 switch shuts off the cruise control when the driver firmly steps on the brakes. The switch is located under the hood of the vehicle and is attached to the brake master cylinder on one end and wired to the cruise control on the other.
On most of its models, Ford designed the switch to be powered -- or "hot" -- at all times, even when the vehicle is off and the key is removed from the ignition.
Inside the switch, a thin film barrier separates brake fluid from the switch's electrical components. Investigators say fires can occur when the film cracks and brake fluid from the master cylinder seeps into the electrical side of the switch.
Ford has already recalled more than 1 million vehicles in two separate recalls to replace the switch.
The first recall was in May 1999, affecting 279,000 Crown Victorias, Grand Marquises and Town Cars for model years 1992 and 1993. The second, issued in January 2005, affected 792,000 vehicles, including model year 2001 F-Series SuperCrews and 2000 Expeditions, Navigators and F-150 pickups.
But a Ford document obtained by CNN shows the same or similar switch was installed in a total of 16 million vehicles, far beyond what was recalled. Those vehicles include:
# Mark VII/VIII from 1994-1998
# Taurus/Sable and Taurus SHO 2.3 L 1993-1995
# Econoline 1992-2003
# F-Series 1993-2003
# Windstar 1994-2003
# Explorer without IVD 1995-2003
# Explorer Sport/Sport Trac 2002-2003
# Expedition 1997-2003
# Ranger 1995-2003
In March, the National Highway Traffic Safety Administration opened an expanded investigation into more than 3.7 million of the vehicles.
NHTSA says it has received 559 complaints of spontaneous fires, 253 of them in unrecalled models, and its latest investigation includes the 1995 model years of the F-150, Expedition and Lincoln Navigator vehicles.
Ford says it has initiated its own investigation and is cooperating with the NHTSA probe.
"We have identified specific populations of vehicles in which the speed-control deactivation switches have had increasing rates of failures and fires," said Ford spokeswoman Kristen Kinley in a written response to questions submitted by CNN.
"When we have seen the fire reports increasing, we have recalled those vehicles and replaced those switches. Ford has used the basic switch design in a large number of vehicles and the risk of fire related to the switch is much different in those certain populations that we have recalled."
She added, "It is important to understand that all speed control systems are not identical in Ford vehicles. ... In those populations with an increasing fire report rate, we stopped using the switch through the recall process. ... The switch has performed well in many models for many years."
In another statement to CNN, Kinley said "we have been asked why we have not expanded the recall. The last thing we want to do is make an important safety decision on incorrect or incomplete information."
Kinley also said, "We have not determined at this time that there is a defect with the switch, but for reasons we still do not understand the switch is failing ... and we are trying to understand why."
Ford no longer uses switch
But, in a recall notice to owners of 2000 F-150s, Expeditions, Navigators and 2001 F-150 SuperCrews, the company seemed less equivocal about the switch. The "switch may overheat, smoke or burn which could result in an underhood fire," it said. "This condition may occur either when the vehicle is parked or when it is being operated, even if the speed control is not in use."
The company stopped using the switch altogether as of the 2004 year model, and is now using a new design.
Meanwhile, the Oyola-Hernandez family has hired a lawyer to reach a financial settlement with Ford but have not filed a lawsuit against the company.
The company says it has not yet investigated their auto insurance claim, but notes that the insurance industry reports about 100,000 noncollision fires per year involving nearly all makes and models sold.
"Simply because we have allegations of fire doesn't mean they are necessarily linked to the speed-control deactivation switch," Kinley said.
The charred remains of their house were recently demolished. But, the family has not been able to rebuild.
After the fire, they moved in with Hernandez's mother, who lives nearby. Since then, after reinstating their home insurance, they have moved into a rented house. Their insurance company sent them $120,000 but rebuilding their home is estimated to cost $185,000. They are hoping Ford will reimburse them for the difference.
They are, once again, a one-car family. This one also is a Ford -- a 1997 Explorer -- and it, too, contains the suspect switch, which has not been recalled. The family parks it on the street instead of the garage.
CNN Investigative Producer Pia Malbran contributed to this story
#5
06-17-2005
Member
Joined: Aug 2004
Posts: 1,072
Likes: 0
From: Wesley Chapel, FL
It's a tall red pressure switch attached to the front of the master cylinder. I even have the stupid thing on my NON CRUISE equipped 01.
Ford's answer is a lame video filled with double talk
http://www.ford.com/en/innovation/sa...iseControl.htm
Basically, their response is something I remember from the movie "Fight Club"
"We will do the math, and determine if it's cheaper for Ford to pay off lawsuits from burn victims or do a recall. In the meantime, please continue to buy Ford"
I'm looking through my service CD to see if you can just disconnect the darn thing, but I'll probably need Bob and John's input on this one.
Ford's answer is a lame video filled with double talk
http://www.ford.com/en/innovation/sa...iseControl.htm
Basically, their response is something I remember from the movie "Fight Club"
"We will do the math, and determine if it's cheaper for Ford to pay off lawsuits from burn victims or do a recall. In the meantime, please continue to buy Ford"
I'm looking through my service CD to see if you can just disconnect the darn thing, but I'll probably need Bob and John's input on this one.
#6
06-17-2005
Originally Posted by SilverTank
I'm looking through my service CD to see if you can just disconnect the darn thing, but I'll probably need Bob and John's input on this one.
#7
06-17-2005
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Joined: Aug 2004
Posts: 1,072
Likes: 0
From: Wesley Chapel, FL
Originally Posted by rwenzing
The irony is that the Deactivation Switch is a redundant safety device intended to cancel the speed control in the unlikely event that the Brake Pedal Position switch fails to do so. It is also an input to the ABS module and one might assume that it has a similar function there. I am not going to say it's OK to unplug a safety device although I've heard that many dealers are doing just that. Kind of a "lesser of two evils" decision.
#10
06-17-2005
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Joined: Jun 2004
Posts: 166
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From: East Helena, Montana
#12
06-17-2005
Member
Joined: Aug 2004
Posts: 1,072
Likes: 0
From: Wesley Chapel, FL
Some stories document the vehicles included in the recall, and some document the vehicles with the switch. From what I've seen, many Fords since 1995 have that switch. BUT Ford doesn't want a 50 million vehicle recall, so they are saying only "certain" vehicles are effected. It's a big CYA, Bryan has that right.
#14
06-17-2005
Originally Posted by SilverTank
Thanks for the input Bob. I really hate those "darned if you do, burned if you don't" decisions. What's your personal opinion on this? Are you leaving yours connected for now?
#15
06-17-2005
Originally Posted by jmacmaster
The first post in this thread has an article saying that the 03 Rangers are included in the years that have a switch problem. I've read at least 3 or 4 news articles that said that the 03 Rangers were NOT included in the years that had a switch problem. What gives?
In addition, the 2003's and late 2002's supposedly have a different and hopefully better switch made by a different vendor. The suspect switches were produced by Texas Instruments.
#16
06-17-2005
Member
Joined: May 2004
Posts: 2,223
Likes: 1
From: Merritt Island, FL
CNN's "investigation" is either misinformed, mislead, or choosing to ignore reality.
The design of the switch is not the primary flaw (although it is flawed) and not, in my opinion, the primary cause of the fires. The primary problem is that some of these switches are wired to constant battery power, meaning they can overheat when vehicle motion isn't pumping cooling air through the engine bay. Even if your truck has that model of switch, if it isn't wired to CONSTANT battery power, then it is not a likely candidate for failure. To the best of my knowledge, in Rangers and all the other vehicles that CNN is listing as having the switch (*cough*for no other reason than to produce ratings*cough*,) the switch is wired either to accesory power, so its only powered up with the key or motor on, or its wired to a "battery saver" circuit (like your dome-lights, they will shut off after a pre-determined amount of time.)
Its the constant power, combined with heat fatigue and a potential design flaw, that is causing the fires. If the switches are unpowered, even if they are of a faulty design, the barrier will fail while there is no power to the switch to ignite the brake fluid, and the fluid will leak out, causing other mechanical trouble, but not igniting when power is applied.
The only cases where I think its a valid concern would be vehicles that are left idling for long periods of time (on the order of hours) like police and emergency vehicles.
The simple fact is that driving your truck provides the cooling that prevents the switch from failing, or even suffering fatigue. I'd be willing to bet that the flaw with the switch is that the circuitry generates some amount of heat, beyond that generated by the engine bay or the brake fluid, that over time, when powered 24/7, causes fatigue in the switch. I'd bet that cars that aren't constant wired will never experience a problem.
edit: if Bob is right (and I have no reason to doubt him,) and the older trucks have constant power, I wouldn't wait for a recall that may or may not happen, I'd re-wire the switch to operate off a suitable (amperage wise) circuit that is either acc. powered or on battery saver.
One other side note: I work with Ford service writers all day every day. They're there to help you, but they didn't design or build your truck, and no matter how much you yell at them, they can't replace your switch free of charge until Ford releases a recall, and even then they sometimes don't recieve the authorization for a week or two after the recall hits the media, and even then its sometimes a few more weeks until enough parts are available to do the recall on everyones' cars! Long story short: don't call your dealership and yell at someone over this. Its not their fault, and they want to help you. If you are courteous to them, they will do everything in their power to help you, if they have anything within their power that CAN help you. Today I've seen two service writers who look like they're ready to have nervous breakdowns from idiots calling and yelling at them about this CNN report. Its not fair, its not right, and its not their fault.
The design of the switch is not the primary flaw (although it is flawed) and not, in my opinion, the primary cause of the fires. The primary problem is that some of these switches are wired to constant battery power, meaning they can overheat when vehicle motion isn't pumping cooling air through the engine bay. Even if your truck has that model of switch, if it isn't wired to CONSTANT battery power, then it is not a likely candidate for failure. To the best of my knowledge, in Rangers and all the other vehicles that CNN is listing as having the switch (*cough*for no other reason than to produce ratings*cough*,) the switch is wired either to accesory power, so its only powered up with the key or motor on, or its wired to a "battery saver" circuit (like your dome-lights, they will shut off after a pre-determined amount of time.)
Its the constant power, combined with heat fatigue and a potential design flaw, that is causing the fires. If the switches are unpowered, even if they are of a faulty design, the barrier will fail while there is no power to the switch to ignite the brake fluid, and the fluid will leak out, causing other mechanical trouble, but not igniting when power is applied.
The only cases where I think its a valid concern would be vehicles that are left idling for long periods of time (on the order of hours) like police and emergency vehicles.
The simple fact is that driving your truck provides the cooling that prevents the switch from failing, or even suffering fatigue. I'd be willing to bet that the flaw with the switch is that the circuitry generates some amount of heat, beyond that generated by the engine bay or the brake fluid, that over time, when powered 24/7, causes fatigue in the switch. I'd bet that cars that aren't constant wired will never experience a problem.
edit: if Bob is right (and I have no reason to doubt him,) and the older trucks have constant power, I wouldn't wait for a recall that may or may not happen, I'd re-wire the switch to operate off a suitable (amperage wise) circuit that is either acc. powered or on battery saver.
One other side note: I work with Ford service writers all day every day. They're there to help you, but they didn't design or build your truck, and no matter how much you yell at them, they can't replace your switch free of charge until Ford releases a recall, and even then they sometimes don't recieve the authorization for a week or two after the recall hits the media, and even then its sometimes a few more weeks until enough parts are available to do the recall on everyones' cars! Long story short: don't call your dealership and yell at someone over this. Its not their fault, and they want to help you. If you are courteous to them, they will do everything in their power to help you, if they have anything within their power that CAN help you. Today I've seen two service writers who look like they're ready to have nervous breakdowns from idiots calling and yelling at them about this CNN report. Its not fair, its not right, and its not their fault.
Last edited by Wowak; 06-17-2005 at 11:36 AM.
#17
06-17-2005
Here is the problem as I understand it.
It is not a question of the Deactivation Switch overheating as a direct result of the lack of airflow, although this may be a contributing factor. The root cause is the leaking seals within the Deactivation Switch that allow brake fluid to enter the part of the switch with the electrical contacts. The conductive brake fluid provides an unintended current path to ground, increasing the amperage through the switch and overheating it and the leaked brake fluid within the electrical part of the switch. Brake fluid is fairly safe compared to other fluids in a vehicle BUT it is still flammable. Apparently, this is where the fires start.
So, there appear to be two contributors to the failures on the affected vehicles:
(1) B+ available to the Deactivation Switch at all times through a 7.5A fuse shared with the Brake Pedal Position switch;
(2) A leaking switch seal that allows a path to ground through the brake fluid and allows the brake fluid to become the combustible element that could start a fire.
The 2003+ wiring method (also apparently used on very late 2002MY trucks) eliminates problem (1) by reassigning the DS to its own dedicated 2A fuse that is hot only when the ignition is on.
Resourcing the DS from a different vendor will hopefully eliminate the other piece of the equation.
It is not a question of the Deactivation Switch overheating as a direct result of the lack of airflow, although this may be a contributing factor. The root cause is the leaking seals within the Deactivation Switch that allow brake fluid to enter the part of the switch with the electrical contacts. The conductive brake fluid provides an unintended current path to ground, increasing the amperage through the switch and overheating it and the leaked brake fluid within the electrical part of the switch. Brake fluid is fairly safe compared to other fluids in a vehicle BUT it is still flammable. Apparently, this is where the fires start.
So, there appear to be two contributors to the failures on the affected vehicles:
(1) B+ available to the Deactivation Switch at all times through a 7.5A fuse shared with the Brake Pedal Position switch;
(2) A leaking switch seal that allows a path to ground through the brake fluid and allows the brake fluid to become the combustible element that could start a fire.
The 2003+ wiring method (also apparently used on very late 2002MY trucks) eliminates problem (1) by reassigning the DS to its own dedicated 2A fuse that is hot only when the ignition is on.
Resourcing the DS from a different vendor will hopefully eliminate the other piece of the equation.
#19
06-17-2005
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Joined: Jun 2004
Posts: 2,070
Likes: 0
From: Altamonte Springs FL
#21
06-17-2005
For the 2001~2002(early), the Deactivation Switch and the Brake Pedal Position switch are both powered thru dash fuse 9 (7.5A hot at all times)
For the 2002(late)~2003, the Brake Pedal Position switch alone is powered thru dash fuse 9 (7.5A hot at all times). Ford added a dedicated fuse for the Deactivation Switch (2A hot in RUN only). It is in the previously unused dash fuse position #6.
2004-on continue to use separate fuses for these switches. The fuses are located in the Smart Junction Box (PS kick panel).
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
It is possible to add a non-standard fuse to the 2003-back dash fuse panel but it is not real easy. I added one for my remote CD changer by disassembling the fuse panel and adding a junkyard terminal/pigtail to an unused position in the dash panel.
For the 2002(late)~2003, the Brake Pedal Position switch alone is powered thru dash fuse 9 (7.5A hot at all times). Ford added a dedicated fuse for the Deactivation Switch (2A hot in RUN only). It is in the previously unused dash fuse position #6.
2004-on continue to use separate fuses for these switches. The fuses are located in the Smart Junction Box (PS kick panel).
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
It is possible to add a non-standard fuse to the 2003-back dash fuse panel but it is not real easy. I added one for my remote CD changer by disassembling the fuse panel and adding a junkyard terminal/pigtail to an unused position in the dash panel.
#23
06-17-2005
#24
06-17-2005
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Joined: Feb 2005
Posts: 594
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From: Wellington, FL
#25
06-18-2005
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Joined: May 2004
Posts: 2,223
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From: Merritt Island, FL
