NHTSA Complaint #10259543 — 1999 FORD WINDSTAR

I HAVE A 1999 FORD WINDSTAR SEL WITH TRACTION CONTROL THAT I PURCHASED NEW JANUARY OF 1999. IT HAS NEVER BEEN OUTSIDE OF SOUTHERN CALIFORNIA AND IS STORED INSIDE. CURRENT MILEAGE IS 140,000. THIS ABS PROBLEM STARTED AFTER WARRANTY PERIOD EXPIRED AT APPROX 39,000 MILES. THE VAN DEVELOPED AN "ABS" LIGHT AND "TRAC OFF" LIGHT. DEALERSHIP DIAGNOSIS WAS A "FAULTY ABS MASTER RELAY" (CODE C1185 AS WELL AS SEVERAL OTHERSREQUIRING A NEW ABS MODULE TO THE TUNE OF MORE THAN 1200$. WITH THE OTHER PROBLEMS IE: HAVING TO REPLACE THE VACUUM HOSES, INTAKE MANIFOLD, VALVE COVER, DOOR SEALS, HEATER BLEND DOOR, INTERIOR LIGHT FLICKERING, AND TRANSMISSION 3 TIMES OVER THE LAST 9 YEARS, THIS WAS ONE FIX WE ELECTED TO FORGO AS I PERFORM ALL MAINTENANCE OUTSIDE THE DEALERSHIP AND THIS SI A DEALER ONLY FIX. I HAVE BEEN FOLLOWING THIS FOR YEARS WITH INTEREST AND JUST NOW DECIDED TO FILE AS THERE APPEARS TO BE THOUSANDS WITH THIS SAME PROBLEM. DASH LIGHTS HAVE BEEN ON FOR THE LAST 100,000 MILES. APPARENT PROBLEM AS FOUND ON WEB - ABS ECM FAILURE - ABS BRAKE LIGHT. 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