NHTSA Complaint #10618933 — 2007 FORD EXPEDITION

THE WIRING HARNESS FROM THE TRANSMISSION TO THE ENGINE COMPARTMENT CROSSES OVER THE CATALYTIC CONVERTER ON THE PASSENGER SIDE. THERE ARE A SERIES OF CLIPS THAT ARE SUPPOSED TO HOLD THE WIRE HARNESS CLOSE TO THE UNDER BODY OF THE CHASSIS. THESE CLIPS PREVENT THE WIRING HARNESS FROM TOUCHING THE CATALYTIC CONVERTER. DURING USE, THE CATALYTIC CONVERTER GETS HOT AND THIS HEAT DEGRADES THE PLASTIC CLIPS TO THE POINT WHERE THE ARE BRITTLE AND FAIL. THIS CAN RESULT IN THE WIRE HARNESS CONTACTING THE CATALYTIC CONVERTER. THE HEAT FROM THE CATALYTIC CONVERTER SUBSEQUENTLY DESTROYS THE WIRING AND INSULATION TO THE POINT THAT THE ECM RECEIVES ERRONEOUS INDICATIONS FROM THE TRANSMISSION. IF EXPOSED FOR SUFFICIENT TIME THE CONDITION COULD CAUSE AN ACCIDENT DUE TO THE TRANSMISSION BEGIN IN LIMP MODE, SUDDENLY FAILING OR A FIRE DUE TO THE WIRING HARNESS IGNITING. *TR