NHTSA Complaint #763020 — 1995 FORD WINDSTAR

I WAS DRIVING FROM WISCONSIN TO PENNSYLVANIA AT NIGHT. IN OHIO, I NOTICED A SIGNIFICANT LOSS OF POWER, AND "WHOOSHING" NOISE FROM UNDER CHASSIS, GRADUALLY GETTING WORSE OVER A COUPLE OF HOURS. AT THAT POINT, THE CHECK ENGINE LIGHT ALSO CAME ON. AFTER ARRIVING IN PITTSBURGH (AND AFTER CHRISTMAS HOLIDAY) I TOOK THE CAR TO A MUFFLER SHOP. AS I EXPECTED, ONE OF THE CATALYTIC CONVERTORS WAS CLOGGED. ON DIAGNOSING THE PCM FAULT CODES, THEY DISCOVERED THAT THE RUBBER HOSES CONNECTING TO THE DPFE (DIFFERENTIAL PRESSURE FEEDBACK EGR) SENSOR WAS NEARLY COMPLETELY MELTED AWAY (BECAUSE OF THE INCREASED EXHAUST BACKPRESSURE FROM THE CAT FAILURE???). I WAS PREPARING THE CAR FOR ANOTHER LONG-DISTANCE TRIP ON 6/10/02 WHEN I DISCOVERED THAT THE PLASTIC AIR INTAKE PLENUM AND THE WIRING HARNESS IN THAT AREA WERE DAMAGED BY HEAT, AS WELL. THE AREA OF DAMAGE IS RIGHT IN THE AREA OF THE METAL TUBES COMING FROM THE EXHAUST SYSTEM THAT THE RUBBER HOSES TO THE DPFE SENSOR CONNECT TO. ABOUT 8 OF THE WIRES HAD THEIR INSULATION COMPLETELY BURNED THROUGH (ABOUT 1" IN LENGTH). MANY OF THE REST OF THE WIRES HAD EMBRITTLED INSULATION, OR THE INSULATION WAS MELTED TOGETHER (THERE SEEM TO BE ABOUT 50 CONDUCTORS IN THE WIRING HARNESS AT THAT LOCATION). I'M REALLY QUITE SURPRISED THAT NO FUSES BLEW, SINCE THE BARE WIRES WERE ALL ADJACENT TO EACHOTHER (ON THE BACK SIDE OF THE WIRE BUNDLE, OUT OF SIGHT IF YOU'RE NOT LOOKING CLOSELY). I HADN'T DETECTED ANY ELECTRICAL FAILURES AT THE TIME, OR DURING THE INTERVENING 6 MONTHS, BUT THIS WAS CLEARLY A FIRE HAZARD. I HAVE SOME REASONABLY CLEAR DIGITAL PHOTOGRAPHS OF THE DAMAGED WIRES (TAKEN WHILE I REPAIRED THE INSULATION ON ALL OF THE CONDUCTORS WITH VINYL ELECTRICAL TAPE). I'LL BE HAPPY TO EMAIL THEM TO YOU IF YOU'RE INTERESTED.*AK