NHTSA Complaint #10222169 — 2003 FORD WINDSTAR

BOTH THE ABS LIGHT AND THE EMERGENCY BRAKE LIGHT COME ON IN MY 2003 FORD WINDSTAR ONCE THE VEHICLE GETS WARMED UP. I HAVE CONDUCTED EXTENSIVE RESEARCH AFTER HAVING A MECHANIC GIVE ME THE CODE THAT THE VAN IS THROWING (C1185) AND FOUND THE FOLLOWING: THE BRAKE PRESSURE DIFFERENTIAL DEACTIVATION SWITCH (2B264) LOCATED UNDER THE MASTER CYLINDER (BEHIND THE AIR FILTER) OVER TIME DEVELOPS A LEAK. THIS CAUSES A SHORT AND A FUSE TRIP, FUSE #10. THIS LEAK CAUSES BRAKE FLUID TO WICK DOWN TWO WIRES TO THE ABS BRAKE MODULE (2C219). THE FLUID ACCUMULATES ON THE POWER CONNECTORS FOR THE ABS BRAKE SYSTEM WHICH ARE POWERED BY FUSES 101 AND 102 AND ARE BOTH 40 AMP. THE FLUID ATTRACTS MOISTURE, ROAD SALT AND LEADS TO A FIRE WHEN THE FLUID AND MOISTURE ACT AS CONDUCTOR BETWEEN THE HOT LEADS AND GROUND. THIS SWITCH HAS BEEN THE SUBJECT OF OTHER FORD RECALLS, JUST NOT THE WINDSTAR VAN YET. BELOW IS A PICTURE OF THE SWITCH IN QUESTION. NOTICE THE FLUID THAT LEAKED ON THE PART BELOW IT. THIS SWITCH WILL CAUSE CRUISE CONTROL PROBLEMS, SPEEDOMETER, ODOMETER AND ABS BRAKE SYSTEM PROBLEMS. THE ISSUE OF THE ABS BRAKE LIGHT IS CRITICAL IN THAT THE ABS BRAKE SYSTEM DOES NOT FUNCTION AS DESIGNED BY FORD. THE ISSUE IS CAUSED BY HEAT IN THE ABS (ANTI-LOCK BRAKE SYSTEM) ECM (ELECTRONIC CONTROL MODULE) (2C219) MODULE CAUSING EXPANSION OF A LARGE ALUMINUM PLATE (HEAT SINK) IN THE ECM WHICH IS ATTACHED TO THE ECM MAIN CIRCUIT BOARD AT ALL POINTS. THE EXPANSION OCCURS WHEN THE UNIT GETS WARM ESPECIALLY IN THE SUMMER MONTHS AND CAUSES INTERMITTENT ELECTRICAL CONNECTION IN THE UNIT BECAUSE THE FRAGILE BOARD IS BEING STRETCHED AND MALFORMED. THE CODE MOST COMMONLY SCANNED BY PROFESSIONAL MECHANICS IS CODE C1185. SEEN BY US OWNERS AS A YELLOW ABS BRAKE LIGHT. *TR