NHTSA Complaint #10368694 — 2002 FORD WINDSTAR

SERIOUS INTERMITTENT ELECTRICAL ISSUES WITH 2002 FORD WINDSTAR. BREAK AND ABS LIGHT HAVE BEEN ILLUMINATED INTERMITTENTLY IN THE INSTRUMENT CLUSTER PANEL SINCE PURCHASING THE CAR IN OCTOBER 2007. THEN IN MARCH 2010, AFTER SMELLING ELECTRICAL BURNING, THE BATTERY LIGHT BEGAN INTERMITTENTLY ILLUMINATING AND GO OFF WHEN GAS IS APPLIED FOR A FEW MOMENTS. ASSUMING POSSIBLE ALTERNATOR OR BATTERY ISSUE, CHANGED OUT THE TWO COMPONENTS. BREAK AND ABS LIGHT AND BATTERY AGAIN BEGAN ILLUMINATING, AND DOOR LOCKS BEGAN NOT WORKING. FORD DEALER PERFORMED 2009 ABS RECALL CORRECTION, BUT ELECTRICAL ISSUES REMAINED. THEN ALL ELECTRICAL COMPONENTS STOPPED WHILE I WAS DRIVING WITH MY CHILDREN ON A BUSY STREET. LOST POWER STEERING, DOORS ALL LOCKED, BREAKS WENT OUT, ODDLY THE INTERIOR LIGHTS BLINKED ON AND OFF LIKE AN AIRPLANE EMERGENCY LIGHTING WOULD DURING A CRASH LANDING. UNABLE TO UNLOCK BACK DOOR TO REMOVE MY TODDLER FROM THE CAR SEAT, AND HAD TO PRAY NO ONE WOULD SLAM ME FROM BEHIND WHILE I CRAWLED INTO THE BACKSEAT AND UNLATCHED HIM (BECAUSE BACK LIGHTS WERE NOT LIT) THEN EXITED THE CAR. HAD TO BE JUMPED TO RESTART. CHANGED 3 BATTERIES AND 4 ALTERNATORS (2 WERE MOTOR CRAFT) SINCE MARCH 2010. ONE ALTERNATOR BLEW WITHIN MOMENTS AFTER THE CAR WAS STARTED AFTER CHANGING IT. MECHANIC MENTIONED HE NOTICED AN ARC FLASH PRIOR TO ITS BLOWING. REPLACED ALL NEW WIRES GOING INTO AND OUT OF THE ALTERNATOR, ALL NEW BATTERY CABLES. REPLACED SERPENTINE BELT AND SEVERAL FUSES. BATTERY LIGHT STILL COMES ON. TOOK VAN TO FORD DEALERSHIP, WHERE THEY WITNESSED AND ACKNOWLEDGED THE ILLUMINATED BATTERY LIGHT, HOOKED VAN UP TO ELECTRICAL TEST EQUIPMENT, AND FOUND NOTHING ($100). HOOKED IT UP TO THE REGULAR DIAGNOSTICS TEST EQUIPMENT (ANOTHER $100) TRIED TO SELL ME AN INTAKE MANIFOLD FOR $500 INCLUDING LABOR (I DIDN'T BITE). THEY REPLACED THE 2 DOOR ACTUATORS ON THE FRONT DOORS ($300) AND THEN TOLD ME THEY WERE UNABLE TO DIAGNOSE THE ACTUAL ELECTRICAL PROBLEM. LIGHTS STILL LIT. CAR RELIABILITY GONE