NHTSA Complaint #10352651 — 2001 FORD WINDSTAR

I HAVE A 2001 FORD WINDSTAR WHICH IS SHOWING SIGNS OF A SUB-FRAME CORROSION FAILURE SIMILAR TO THE ONE DESCRIBED IN INVESTIGATION PR 10-026. THERE IS A "U-SHAPED" SUBFRAME ELEMENT WHICH CONNECTS TO THE MAIN FRAME NEAR THE OUTBOARD SIDE OF BOTH FRONT SEATS AND EXTENDS FORWARD AROUND THE FRONT OF THE CAR. IT DOES APPEAR VARIOUS SUSPENSION AND STEERING MEMBERS ARE CONNECTED TO THIS SUB-FRAME. THE PASSENGER-SIDE END OF THIS SUB-FRAME WHERE IT CONNECTS TO THE VEHICLE FRAME SHOWS SEVERE RUSTING AND METAL DELAMINATION AND A CRACK HAS FORMED ON THE END. THE DRIVER-SIDE END OF THIS SUBFRAME SHOWS NORMAL WEAR AND IS NOT IN IMMEDIATE RISK OF FAILURE. THE CORROSION TO THE PASSENGER-SIDE END IS EXCESSIVE AS COMPARED TO THE DRIVER'S SIDE AND OTHER FRAME ELEMENTS IN THE VICINITY. SOMETHING IS ACCELERATING THE CORROSION ON THE RIGHT SIDE. IT MAY BE DUE TO THE CONDENSATE DRAIN FROM THE AIR-CONDITIONING SYSTEM. AT THIS TIME, THE SUB-FRAME HAS NOT FAILED BUT THE VEHICLE REPRESENTS A SIGNIFICANT SAFETY RISK SINCE FAILURE-RELATED CRASHES HAVE BEEN REPORTED. THE REPAIR COSTS ARE ESTIMATED TO BE IN EXCESS OF $2000 FOR FRAME REPLACEMENT. I BELIEVE THAT FORD SHOULD QUICKLY DEVELOP AND DEPLOY A MEANS OF REINFORCING THE FRAME MEMBER AND OFFER THE REPAIR VIA RECALL TO WINDSTAR OWNERS. SINCE THE PARTS ARE CURRENTLY STILL ON MY VEHICLE, I CAN TAKE PHOTOGRAPHS SHOWING THE DETERIORATION OF THE SUB-FRAME ENDS. AS A SIDE NOTE: MY WINDSTAR IS EQUIPPED WITH THE REARSEAT AIR-CONDITIONING SYSTEM. THE EVAPORATOR IS IN THE REAR QUARTER-PANEL ON THE DRIVER'S SIDE IN THE REAR OR THE VEHICLE. WHILE THIS AFFECTED COMPONENTS DO NOT APPEAR TO BE A CRITICAL PART OF THE VEHICLE'S STRUCTURE, THERE IS SIGNIFICANT CORROSION TO THE PARTS WHICH ARE IN THE PATH OF THE CONDENSATE DRAIN FOR THE REAR A/C SYSTEM AS WELL. THIS SEEMS TO CONFIRM THE BELIEF THAT A/C CONDENSATE RUN-OFF IS A KEY FACTOR IN THE SUB-FRAME CORROSION ISSUE. *TR