NHTSA Complaint #718052 — 1992 FORD THUNDERBIRD

IN THE U.S. MILITARY STATIONED IN EUROPE. FUEL PUMP AND RELAY MALFUNCTIONED. WHILE INSTALLING NEW FUEL PUMP AND RELAY, THE FORD TECHNICIAN FOUND THE WIRING HARNESS PROVIDING CURRENT TO THE PUMP WAS IMPROPERLY INSTALLED OR WAS A FAULTY DESIGN. IT HAD CHAFFED THROUGH THE HARNESS CASING EXPOSING THE CHARRED AND MELTED WIRES INSIDE. SUBSEQUENT CHAFFING OF INNER WIRES CAUSED A SHORT IN THE CIRCUIT AND MELTING OF THE WIRES THEMSELVES. DUE TO THE PROXIMITY OF THE SHORT, AN EXPLOSION COULD OCCUR IF FUEL VAPORS ARE PRESENT. THE TECHNICIAN WAS SURPRISED IT HAD NOT EXPLODED. THIS VEHICLE HAS A CURRENT RECALL FOR OTHER FUEL SYSTEM DEFECTS. A COMBINATION OF THE 2 COULD BE DEADLY IF THE OWNER IN UNAWARE OF EITHER PROBLEM AREA. I HAVE AND WILL RETAIN THE HARNESS FOR FURTHER INVESTIGATION IF NEEDED. *AK