NHTSA Complaint #10745407 — 2003 FORD EXCURSION

TL* THE CONTACT OWNS A 2003 FORD EXCURSION. THE CONTACT STATED THAT THE GEAR SHIFT LEVER SPARKED A FIRE AND THE WIRING OF THE SHIFTER BEGAN TO MELT. THE VEHICLE WAS ENGULFED IN SMOKE SHORTLY AFTER THE FAILURE. THE CONTACT IMMEDIATELY SHUT OFF THE VEHICLE AND DISCONNECTED THE BATTERY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN STATED THAT THE WIRING INSULATION OF THE LEVER HAD WORN AND CAUSED THE FAILURE. AS A RESULT, THE GEAR SHIFT ASSEMBLY WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 145,000. IN ADDITION, THE CONTACT STATED THAT THE SILVER CIRCUIT BOX INSIDE OF THE FUSE BOX MELTED AND CAUGHT ON FIRE. WHEN THE FAILURE OCCURRED, ALL THE GAUGES ON THE INSTRUMENT PANEL AND THE ALTERNATOR FAILED CAUSING THE VEHICLE TO STALL. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE FUSE BOX WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED HIM THAT THE FUSE BOX WAS DISCONTINUED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED SHORTLY AFTER. IN ORDER TO REMEDY THE FAILURE, A MODIFICATION HAD TO BE MADE TO BYPASS THE MELTING CURRENT BY PLACING AN EXTERNAL WIRE AND CIRCUIT BREAKER. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 140,000.