NHTSA Complaint #10533315 — 1998 FORD WINDSTAR

MY WINDSTAR HAS ABOUT 155,000 MILES ON IT AND A 25 GALLON TANK. ABOUT SIX MONTHS AGO IT CUT OFF ON THE INTERSTATE IN FRONT OF A TRACTOR TRAILER WITH MY DAUGHTER DRIVING. IT HAD JUST TRAVELED ABOUT 200 MILES AND IT WAS RAINING HARD. WE HAD IT TOWED TO A FORD DEALER AND ALL HE REPORTED WAS THE FUEL PUMP FUSE BLEW. THE SECOND EVENT WAS ON VACATION AND AFTER DRIVING ABOUT 175 MILES. AGAIN IT WAS POURING DOWN RAIN. I FIGURED IT WAS MOISTURE RELATED AND LET IT SIT THREE DAYS AND THE IDLE CLOSE TO 1/2 HOUR. FINALLY I DROVE IT ABOUT 45 MINUTES AND IT SEEMED FINE SO WE DROVE HOME. AGAIN AT ABOUT 150 MILES AND HEAVY RAIN IT BLEW THE FUSE ABOUT 5 MILES FROM HOME. AFTER TWO MORE FUSES WE MADE IT HOME. I USED AN AIR COMPRESSOR AND AIR NIBBLER TO CAREFULLY CUT AN ACCESS HOLE IN THE FLOOR OF THE VAN. MY DAUGHTERS CHRYSLER COMES WITH AN ACCESS POINT FOR FUEL PUMP SERVICE. NOW MY VAN HAS ONE TOO. THE ORIGINAL PUMP WAS IN THE TANK. THE WIRES EXPOSED TO FUEL WERE CHAFFED IN 5 SPOTS AND ARCING AT THE PUSH IN CONNECTOR. THE ARCING WAS DUE TO A CRIMP ON A HOSE CLAMP RUBBING THE WIRE NEAR THE PUSH IN PUMP CONNECTOR. THIS RUBBING MAY HAPPEN DUE TO OTHER STORIES I'VE READ ABOUT WHERE THE TANK COLLAPSED FROM VACUUM IN THE TANK. SHAME ON THE PEOPLE WHO DESIGNED THIS PUMP, TANK AND THE ASSEMBLY PROCESS. BY THE WAY I'M A QUALITY ENGINEER AT AN ENGINE FACTORY. I EXPECT A FUEL PUMP TO WEAR OUT -- NOT SHORT OUT. *TR