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FORDS WITH A KNOWN HISTORY OF FIRES

NHTSA DEFECT INVESTIGATIONS

Action: EA90-005
Manufacturer: FORD
M/M/Y: Taurus/T-Bird 1987, 1988
Subject: PWR Seat Malfunct Fire
Opened: 31-Oct-89
Closed: 29-Mar-91
Comments: 91V-036 [PE89-125] 

Action: EA90-031
Manufacturer: FORD
M/M/Y: B600, B700, F600, F700, F800
Subject: Engine Compartment Fire
Opened: 28-Jun-90
Closed: 31-Oct-91
Comments: PE90-045 

Action: EA95-027
Manufacturer: FORD
M/M/Y: Mercury Villager, 1993
Subject: Front Blower Assembly Fire
Opened: 22-Sept-95
Closed: 17-Nov-95
Comments: 95V-222 [PE95-037] 

Action: PE90-023
Manufacturer: FORD
M/M/Y: F-Series Truck 1983, 1984, 1985, 1986, 1987, 1988
Subject: Fire Heater/AC Plenum
Opened: 05-Dec-89
Closed: 01-Mar-90
Comments: No Defect Trend 

Action: PE95-037
Manufacturer: FORD
M/M/Y: Mercury Villager, 1993
Subject: Front Blower Assembly Fire
Opened: 19-Jun-95
Closed: 22-Sept-95
Comments: EA95-027 

Action: PE96-041
Manufacturer: FORD
M/M/Y: F-Series Medium & Heavy, 1995-96
Subject: Truck Electrical Fire
Opened: 12-Jun-96
Closed: 14-Nov-96
Comments: 

Action: PE96-066
Manufacturer: FORD
M/M/Y: Explorer, 1993-94
Subject: Driver Door Electrical Fire
Opened: 22-Nov-96
Closed:
Comments:

1993 Ford Ecostar
Number of Vehicles: 34
Battery in electric vehicle can fail in a manner which results in fire and can cause personal injury to persons near vehicle. 

1992-95 Ford Tempo, Mercury Topaz, Lincoln Continental, Ford Taurus, Mercury Sable
Number of Vehicles: 75,200
Completion rate: to be provided
During high winds, heavy, drifting snow, and low temperatures, engine cooling fan can become blocked or frozen with snow. Fan motor may not rotate and overheat, which can cause smoke or flames from fan and/or shroud, fan electrical wiring, or fan motor, resulting in vehicle fire. 

1995 Ford Windstar
Number of Vehicles: 112,000
Completion rate: to be provided
Alternator output wire was not connected tightly to power distribution box. This can result in overheating of the connection and vehicle fire. 

1997 Ford F-Super Duty
A plastic coated steel strap was crimped to battery cable for support. Battery cable insulation could have been damaged when the strap was crimped onto the cable. This damage can result in the battery cable developing a short to ground. A shorted battery cable can cause a vehicle fire. 

1997-98 Ford Mercury, Villager
Number of Vehicles: 6,000
Batteries have defective negative post that can cause acid leakage and related corrosion damage, which can cause catastrophic failure of battery, engine fire or battery explosion. 

1988-89 Ford Crown Victoria, Tempo Topaz, Mercury Cougar; 1988-90 Escort, EXP; 1988 Mustang Thunderbird; 1988-93 Aerostar Bronco F150, F250, F350, Grand Marquis; 1988-91 Lincoln Town Car
Number of vehicles: 7,500,000
Ignition switch could experience an internal short circuit which can cause overheating, smoke, and fire in the steering column area. 

1990 Ford Thunderbird Mercury, Cougar
Number of Vehicles: 72
On cars with 3.8 L engines, battery-to-starter cables are longer than specified; excessive cable length could contact engine damper pulley. Cable protective covering and insulation could wear through and cause a direct short to ground, resulting in overheating of the cable insulation and an underhood fire. 

1992-94 Ford Explorer
Number of Vehicles: 61,000
Short circuit can occur in remote power mirror control switch circuit board as result of separated part of contact assembly that bridges positive battery pad switch and adjacent chassis ground pad. Current can overheat printed circuit board and other plastic and elastomeric components of switch assembly, resulting in smoke or fire. 

1992 Ford F-250, F-350
Number of Vehicles: 48,000
Sound insulation on the engine side of the dash panel can contact the exhaust manifold. Contact between the insulation and the hot exhaust manifold may result in a engine compartment fire. 

1993-97 Ford F Super Duty
Number of Vehicles: 64,000
Hot exhaust gases can leak from exhaust gas recirculation (EGR) tube on engine. Hole can develop in flexible section of tube. Heat damage to passenger compartment floor and floor covering can occur and result in vehicle fire. 

1996 Ford Taurus
Fuel pressure regulator located in the fuel engine compartment has a vacuum diaphragm that was damaged during manufacture of regulator. If diaphragm tears or ruptures, liquid fuel could enter intake manifold plenum through vacuum line, release fuel from the air cleaner assembly or the exhaust system and result in a fire. 

1990 Ford Truck F-150, F-250, F-350
Number of Vehicles: 1,100
On light duty trucks equipped with dual fuel tanks, incorrectly installed fuel line connectors have fuel supply and return lines crossed. Fuel could be transferred from one tank to the other, possibly resulting in fuel overflow and spillage; in presence of an ignition source, a fire could occur. 

1991 Ford Lincoln Town Car
Number of Vehicles: 26,000
Distorted fuel lines in engine compartment may contact the steering column universal joint and cause damage to the fuel line, resulting in fuel leakage and possibly a fire. 

1993 Ford Mercury Villager
Number of Vehicles: 10,800
Fuel filler hoses may have been cut prior to installation by a utility knife used to open the shipping box. Fuel leakage can result if the cut extended through the thickness of the hose wall. Leaking fuel can result in an underhood fire. 1993 Ford Mercury Villager Number of Vehicles: 10,800 Fuel filler hoses may have been cut prior to installation by a utility knife used to open the shipping box. Fuel leakage can result if the cut extended through the thickness of the hose wall. Leaking fuel can result in an underhood fire. 

1992-93 Ford Econoline
Number of Vehicles: 1,235
Cargo vans sold to Sears company fleet. The fuel filler hose or fuel filler vent hose may have been damaged by a drill bit used to install a special package for Sears vehicles. If either of the hoses was penetrated by the drill bit, fuel leakage could result, particularly during fueling of the vehicle, and result in fire. 

1993 Ford Mustang
Number of Vehicles: 4,100
The fuel rail that supplies fuel to the fuel injectors has an improperly formed tube which could fracture, causing fuel to leak and cause a fire. 

1990-91 Ford Chassis, F-250, F-350, Super Duty
Number of Vehicles: 89,770
The steel fuel return tubes that connect the frame fuel return lines with the engine fuel rail can contact the pinch weld flange connecting the dash panel to the floor pan. Continued contact leads to abrasion of the steel fuel return tube and eventually results in a fuel leak. A fuel leak may result in a fire, if a source of ignition is present. 

1994 Ford Ranger
Number of Vehicles: 11,400
Front fuel lines on pickups with 3.0 and 4.0-liter engines have a section of flexible hose that is susceptible to cracking. This can allow fuel leakage and result in fire when exposed to a source of ignition. 

1994 Ford Aspire
Number of Vehicles: 26,700
Fuel supply, return and vapor hoses or lines can contact or have inadequate clearance with surrounding components because of improper positioning during assembly. Wear of hose or line can occur, resulting in fuel leakage in the engine compartment and fire. 

1997 Ford Mercury Villager
Four rubber fuel line connector hoses that are supplied to Ford with fuel tank assembly were improperly manufactured. These hoses can develop cracks or splits resulting in fuel leakage and a possible fire. 

1992-93 Ford Thunderbird Mercury Cougar
Number of Vehicles: 125,000
Movement of fuel lines causes nylon fuel line jumper to chafe against floor pan. Wear can cause pin hole in one of the fuel lines, resulting in fuel leakage and possible fire. 

1998 Ford Ranger
Number of Vehicles: 2,000
Flexible section of chassis mounted fuel line connecting engine was routed too close to exhaust manifold and line could contact manifold. This could result in damage to fuel line, cause fuel leak, and result in fire. 

1996 Ford Ford Aerostar
Number of Vehicles: 91,000
On truck-vans, insufficient interference fit between fuel tank filler pipe and grommet could result in an inadequate seal which could allow fuel to seep from the joint. In the presence of an ignition source, fuel leakage could result in a fire. 

1991 Ford Truck Explorer
Number of Vehicles: 25,000
Front heat shield may contact front of the plastic fuel tank, causing cuts or other damage to the extent of the penetration. This could cause vapors to escape and possibly fuel to spill, which could lead to a fire. 

1991 Ford Truck Explorer
Number of Vehicles: 18,000
The hot plate weld which attaches vapor vent valve carrier to top of the plastic fuel tank may partially fracture, allowing fuel vapor to escape from the top of the tank. The escaped vapor or leaked fuel could cause a fire in the presence of an ignition source. 

1989, 1990, 1991 Ford Econoline; 1989 F-150, F-250, F-350
Number of Vehicles: 350,000
Dual function fuel reservoir may malfunction and cause an overfill condition in one of the fuel tanks, resulting in an overflow of fuel past filler cap. Overflow of fuel past filler cap causes a fuel leakage, which can result in fire when exposed to a source of ignition. 

1991 Ford Escort; 1991 Mercury Tracer
Number of Vehicles: 22,000
Fatigue cracks can develop in the solder joint between the fuel return tube and the fuel pump sending unit located at the top of the fuel tank. Should a crack develop, fuel vapor can escape from the tank when the tank is full and a small amount of fuel can leak from the crack and result in fire. 

1991-93 Ford Truck F Super Duty, 1990-93 F-150, F-250, F-350
Number of Vehicles: 1,131,000
Light trucks and chassis cabs with gasoline engines and dual fuel tanks. A malfunctioning check valve within the fuel pump assembly causes a portion of the unused fuel from one tank to be returned to the second tank. When this occurs, the capacity of the second tank can be exceeded, causing fuel spillage which can result in a fire. 1991-94 Ford L800, L900, L9000 Number of Vehicles: 3,200 On heavy duty trucks with Detroit Diesel Series 60 engines, labels reminding service personnel closing fuel tank crossover valves to reopen valves before operating engines were omitted. If the tanks are over half full and vehicle operation was resumed without reopening the fuel tank cross-over valves, pressure could build in one of the tanks and result in rupture of tank, spilling diesel fuel, which can cause a fire. 

1995 Ford Crown Victoria, Lincoln Town Car, Mercury Grand Marquis
Number of Vehicles: 100,000
The seal material between the fuel filler pipe and fuel tank may not have been fully cured during the molding process which could allow fuel to leak and result in fire. 

1996 Ford F Super Duty, F250, F350
Cross member frame gussets were installed with undersized threaded fasteners following a breakdown of the production rivet gun that is generally used. This gusset is the attachment point for the rear strap of the mid-ship fuel tank. Fasteners can separate causing the rear strap of the fuel tank to become disconnected. A loose or disconnected rear strap allows the fuel tank to contact the road surface increasing the risk of a vehicle fire. 

1995 Ford Escort, Mercury Tracer
Number of Vehicles: 64,000
Cracks can develop in plastic fuel tank near heat shield attachment, resulting in fuel leakage if cracks go through fuel tank wall and result in vehicle fire. 

1995 Ford Escort, Mercury Tracer
Number of Vehicles: 600
Plastic fuel tank can exhibit substantial cracking near heat shield attachment, which can result in fuel leakage and fire. 

1989 Ford Crown Victoria
Number of Vehicles: 225
On Flexible Fuel Vehicles with fuel systems modified to operate with gasoline, methanol, or combinations of the two fuels, a glass element that separates electronic circuitry from pressurized fuel may loosen and create an opening that could allow pressurized fuel to enter body of sensor. Under seal deterioration, the housing would not contain the fuel, causing a leak which could lead to a fire. 

1995 Ford Contour, Mercury Mystique
Number of Vehicles: 8,000
Metal shield on outside of plastic fuel filler pipe can develop static electrical charge during refueling of vehicle. Static charge can discharge and serve as an ignition source for fuel vapors in area of filler pipe, resulting in flash vapor ignition and vehicle fire. 

1995 Ford Contour, Mercury Mystique
Number of Vehicles: 28,500
Fuel tank filler pipe opening reinforcement can leak at weld and result in a fire. 

1995 Ford Contour, Mercury Mystique
Number of vehicles: 167,784
Fuel tank filler pipe opening reinforcement, constructed from two separately molded pieces, can leak at the weld and result in a fire. 

1996-97 Ford Contour
Number of Vehicles: 1,800
Natural gas fuel tanks have solenoid shut-off valve that stops fuel flow from fuel tank during some moderate to severe collisions. If vehicle is in collision and natural gas fuel line is damaged, system could leak natural gas and result in fire. 

1998 Ford Mustang
Number of Vehicles: 8,000
Vehicles have missing or inadequately brazed joints between fuel rail body and fuel rail mounting brackets. If bracket separates from rail, rail can lift one or more of injectors, and fuel leakage will result and fire can occur. 

1988-89 Ford Taurus, Mercury Sable
Number of Vehicles: 278,000
Power seat switch wiring is routed over rather than under the front seat support brace, allowing damage by seat cushion spring ends when seat is occupied. The wiring insulation may become abraded, or punctured; an electrical short can occur, possibly resulting in a fire in the seat cushion material. 

1992-93 Ford Crown Victoria
Number of Vehicles: 16,000
Power front seat tracks. Police and fleet vehicles equipped with rubber floor mats and non-powered front seats. An unused power seat harness connector is positioned on the rubber floor mat under the seat. If the vehicle is operated in cold weather areas that have large amounts of salt used for snow and ice control, a puddle of saltwater can accumulate on the rubber floor mats, repeatedly wetting the connector. This will result in corrosion of the connector, causing current to flow between the terminals without tripping the circuit breaker. If this occurs, electrical current can heat the connector and release fumes into the passenger compartment. This can result in a vehicle fire. 

1997 Ford Taurus Windstar, Mercury Sable
Number of Vehicles: 100,000
Low/intermediate servo cover can separate from transaxle while vehicle is being driven. If this occurs, transmission fluid will leak and contact catalytic converter. Catalytic converter temperature may be hot enough to ignite transmission fluid and cause vehicle fire. 

1991 Ford Mercury Capri
Number of Vehicles: 4,200
Rubber tube that connects the automatic transmission to the transmission oil cooler (in the radiator) may disconnect, causing discharge of transmission fluid. If fluid contacts the exhaust manifold or pipe, a fire could result. 

1993 Ford Mercury Capri
Number of Vehicles: 3,750
Automatic powertrain cooling unit and lines. The transmission fluid rubber tube connecting the transmission to the transmission oil cooler located in the radiator can become disconnected from the transmission, resulting in discharge of transmission fluid which could contact the exhaust manifold or the exhaust pipe, resulting in a fire. 

1992-97 Ford Aerostar
Number of Vehicles: 75,000
Vehicles can develop powertrain bending resonance or displacement of transfer case output shaft bushing. Powertrain bending resonance or output shaft bushing displacement can result in structural failure of transmission and/or transfer case. Fluid expulsion, drive shaft separation, or loss of vehicle drive can result, particularly as result of sustained driving at high speed and high ambient temperatures. This can cause loss of vehicle control, and vehicle fire. 

1993 Ford Mercury Villager
Number of vehicles: 48,053
Leaves and other foreign material can enter through the cowl panel air intake during operation of the front heater and/or air conditioning system resulting in a build-up of material in the plenum. This can lead to noise, odors, or ignition of these materials, causing a fire.