NHTSA Complaint #710974 — 1995 FORD WINDSTAR

WHILE ATTEMPTING TO STOP, THE BRAKE PEDAL WENT TO THE FLOOR. PUMPING THE BRAKE PEDAL DID NOT STOP THE VEHICLE AT THIS TIME A LARGE AMOUNT OF SMOKE WAS BILLOWING FROM UNDERNEATH AND AROUND THE VEHICLE. FINALLY FROM DOWNSHIFTING AND USING THE PARKING BRAKE THE VEHICLE WAS BROUGHT TO A STOP. AS A MASTER TECHNICIAN AND SERVICE MANAGER OF A LOCAL DEALERSHIP, I EXAMINED THE VEHICLE AND FOUND A METAL BRAKE LINE THAT CROSSES FROM THE LEFT SIDE OF THE VEH. TO THE RIGHT SIDE IS LOCATED DIRECTLY ABOVE THE CATALYTIC CONVERTER WITH NO PROTECTION FROM HEAT OR OTHER DAMAGE. AT THIS AREA DIRECTLY ABOVE THE CATALYTIC CONVERTER THE BRAKE LINE WAS RUSTED EXCESSIVELY FOR ABOUT 8-10 INCHES. THIS IS THE AREA DIRECTLY ABOVE THE CATALYTIC CONVERTER. NOTHING ELSE IN THIS AREA IS CORRODED OR RUSTED. THE REST OF THIS BRAKE LINE, AS WELL AS THE OTHER LINES ARE IN PERFECT CONDITION. IT SEEMS THAT PLACING A BRAKE LINE ABOVE THE CATALYTIC CONVERTER WITHOUT ANY PROTECTION CAUSES RAPID OXIDATION ONCE THE PROTECTIVE COATING IS DAMAGED FROM THE EXTREME HEAT. THE RUSTED BRAKE LINE DID HAVE HOLES THAT SPRAYED BRAKE FLUID ON THE CATALYTIC CONVERTER CAUSING THE SMOKE. LUCKILY NO FIRE. I REPLACED THIS LINE MYSELF AND STILL HAVE THE OLD ONE IN MY POSSESSION. I WISH NOTHING MORE THAN FOR FORD TO RECALL THESE VEHICLES TO PREVENT ANY UNNECESSARY INJURY OR DEATH. I WAS ON LINE WITH ANOTHER 95 WINDSTAR OWNER WHO EXPERIENCED THE EXACT SAME PROBLEM ONLY HIS CAUGHT ON FIRE AND COST HIM 500.00. HE HAS CONTACTED NHTSA ALSO. THIS IS OUR FIRST STEP AND WILL NOT STOP UNTIL SOMETHING IS DONE. THANK YOU FOR YOUR EFFORTS. TOM