NHTSA Complaint #10608191 — 2006 FORD FOCUS

THE TRUCK LATCH ON MY 2006 FORD FOCUS ZXW WOULD NOT ACTUATE ELECTRICALLY WHEN THE BUTTON ON THE FOB OR ON THE DASH WAS PRESSED DUE TO BROKEN WIRE IN A WIRING HARNESS RUNNING FROM THE INTERIOR TO THE REAR HATCH DOOR. IT WOULD ALSO BLOW FUSE #63 ON THE BACK OF THE INTERIOR FUSE PANEL WHICH MADE REPLACEMENT DIFFICULT (THE FUSE IS REALLY ON THE BACK OF THE FUSE BOX, THE MANUAL RECOMMENDS THAT ONLY THE DEALER SERVICE OR REPLACE THIS FUSE MAKING THIS ISSUE DIFFICULT OR IMPOSSIBLE TO PARTIALLY RESOLVE IMMEDIATELY). UNTIL THIS FUSE COULD BE REPLACED, MY INTERIOR DOOR LOCKS COULD NOT BE ACTUATED ELECTRICALLY (POWER LOCKS OR FOB) WHICH WAS A SAFETY CONCERN AS ANY CHILDREN IN THE BACK SEAT COULD NOT BE EASILY REACHED IN THE EVENT OF AN EMERGENCY. ONE WOULD NEED TO MANUALLY UNLOCK ANY AND ALL DOORS FROM THE INSIDE OF THE VEHICLE. THE CULPRIT WAS WIRING HARNESS THAT HAD WIRES WITH DAMAGE TO THE INSULATION AND TWO BROKEN WIRES. I WOULD BE HAPPY TO SEND ANY AND ALL PICTURES OF THE DEFECTS. THE DAMAGE OCCURS WHEN THE HARNESS BENDS AS THE REAR HATCH IS SHUT DUE TO POOR DESIGN THAT DID NOT INCORPORATE A STAIN RELIEF TO EITHER END OF THE HARNESS WHERE MAXIMUM BENDING STRESSES WOULD OCCUR. THE WIRES MAY HAVE ALSO SHORTED AFFECTING THE BRAKE LIGHT OPERATION, MARKER LAMP OPERATION, AND NUMEROUS OTHER FUNCTIONS AS THERE ARE AN ESTIMATED TEN WIRES THAT RUN IN PARALLEL IN THIS HARNESS AND ALL WIRE EXCEPT TWO HAD MULTIPLE INSULATION DEFECTS THAT POTENTIALLY RESULTING IN SHORTS. THIS IS A DEFINITE SAFETY ISSUE AND ALL HARNESSES THAT HAVE THE POTENTIAL FOR THIS TYPE OF FAILURE SHOULD BE REPLACED OR REPAIRED IMMEDIATELY. *TR