NHTSA Complaint #10457115 — 2002 MERCURY SABLE

WIRE HARNESS FAILURE IN RUBBER BOOTS FROM BODY OF CAR TO REAR LIFT GATE ON STATION WAGON MODEL. INSULATION CRACKING AND WIRE BREAKING COMPLETELY IN FLEXIBLE RUBBER BOOT CAUSES ERRATIC BEHAVIOR AND ULTIMATE FAILURE OF HIGH BRAKE LIGHT, BACK UP LIGHTS, LICENSE PLATE LIGHTS, REAR WINDSHIELD WIPER, REAR WINDOW DEFROSTER, OPEN LIFT GATE AND OPEN REAR WINDOW SAFETY SENSORS AND STEREO SPEAKERS. INSULATION AND WIRING WITHIN BOOT HAS BECOME BRITTLE AND FATIGUED. CLEAN BREAKS IN WIRES FROM OPENING AND CLOSING LIFT GATE ARE EVIDENT. WIRES WHERE INSULATION HAS BROKEN THROUGH ARE COMING IN CONTACT WITH OTHER CIRCUITS WHERE THAT INSULATION HAS BROKEN THROUGH AND RESULTS IN "CONFUSING" OPERATION OF LIGHTS. IE PUT CAR IN REVERSE AND HIGH BRAKE LIGHT COMES ON - PUT FOOT ON BRAKE AND HIGH BRAKE LIGHT GOES OUT. BACKUP LIGHTS DON'T COME ON AT ALL. IE TURN ON REAR WINDSHIELD WIPER AND LICENSE PLATE LIGHT COMES ON. WIRING DOES NOT APPEAR TO HAVE SUFFICIENT NUMBER OF MULTIPLE INTERNAL COPPER STRANDS OR SUPPLE ENOUGH INSULATION TO PROVIDE NEEDED FLEXIBILITY DURING REGULAR OPENING AND CLOSING OF REAR LIFT GATE. BELIEVE THIS TO BE A LATENT SAFETY DEFECT. MANUFACTURER SHOULD HAVE KNOWN DURING DESIGN THAT WIRING IN BOOT TO STATION WAGON LIFT GATE WOULD BE PRONE TO CATASTROPHIC FAILURE WITH REGULAR USE. *JS