NHTSA Complaint #10185421 — 2001 FORD WINDSTAR

IN THE FALL OF 2006 I BEGAN EXPERIENCING ISOLATED INSTANCES WHERE THE BRAKE LIGHTS STAYED ON AFTER THE RELEASE OF THE BRAKE PEDAL. I FIRST NOTICED IT WHEN THE BATTERY WAS DEAD BY THE END OF THE WORK DAY. FREQUENCY INCREASED OVER THE NEXT SEVERAL MONTHS. I FOUND I COULD RESOLVE THE PROBLEM BY LIFTING THE PEDAL SLIGHTLY FROM BEHIND. ON MARCH 12, 2007 THE PROBLEM BEGAN HAPPENING WITH EACH STOP, SO I REMOVED AND EXAMINED THE BRAKE LIGHT SWITCH. IT APPEARED TO BE FUNCTIONING CORRECTLY. I EXAMINED ITS PLACEMENT ON THE BRAKE BOOSTER ROD. THE WEAR PATTERN APPEARED TO BE VERY SLIGHTLY OFF-CENTER. I REINSTALLED THE SWITCH, BUT INSERTED THE SPACER INSERT FROM THE OPPOSITE SIDE. WHEN DISSASSEMBLING, THE SPACER WAS INSERTED FROM THE PASSENGER SIDE. WHEN I REASSEMBLED IT, I INSERTED IT FROM THE DRIVER SIDE. I HAVE DRIVEN THE CAR APPROXIMATELY 1200 MILES AND THE PROBLEM HAS NOT RETURNED. I HAVE PREVIOUS EXPERIENCE AS AN ASE MASTER CERTIFIED MECHANIC.