1999-2003

Ford Windstar Brake, ABS Brake, Cruise Control, and Speedometer/Odometer Electrical Problems

The ideas and suggestions on this page are in no way the opinion of Ford, Ford Motor Company, or any Employee of Ford. The suggestions are offered free and without warranty and are implemented at your own risk.

This page is dedicated to the safety of those that own a Ford Windstar model years 1999 - 2003 (and possibly others). Many owners of these popular vans have encountered any of the following problems. Ford has NOT taken action to solve these critical problems yet. Thru this page and your complaints to the NHTSA.GOV we the owners of Windstars can force Ford into a voluntary recall situation. We forced Ford into a voluntary recall on 10/09/2009. Good job everyone!

RECALL INFO

1/4/2010 - If Ford only installed a fusible link as a solution and you are still having troubles or have new troubles. Please let me know. Address at bottom.

12/29/2009 - Ford in most cases is not doing enough during the recall service to prevent the fires adressed in the recall. Ford dealers are installing a fusable link in the SCDS circuit. This is not enough to prevent fluid from leaking down the wires to the ABS BRAKE unit which has high powered circuits. At a minimum request that Ford replace the defective SCDS switch under the recall.

12/14/2009 - My Windstar is back. It has a new SCDS, Wire Harness, ECU, HCU and 1 wheel speed sensor. They did it right, but that was becuase I had an inside connection and a complete knowledge of the issue.

VERY IMPORTANT: Understand this problem before having Ford do the work. Discuss with the service manager (prior to the work) what he plans to do. If is not what is descibed in the FORD document below. DO NOT have them do the work. You get ONE easy chance to have them do it right. If they do it, but not right you are stuck with it until you can get enough complaints at the NHTSA again to have them open a recall investigation. YOU ARE YOUR OWN BEST ADVOCATE!

11/27/2009 - My van is still in the shop, 24 days now. This gives you an idea of the depth of this issue if there was a fire and parts have to be replaced.

11/26/2009 - Many owners are reporting continued problems after the recall. The NHTSA says to report any problems after the recall was complete. If needed they will open a follow up investigation. Please make sure you report that recall 09S09 was completed by Ford. Please note the recall will only attempt to mitigate a fire hazzard caused by Problem #1 (see below). If fluid did not leak and cause damage to the ABS unit you may be stuck with Problem #2.

11/25/2009 - Recall notices received by owners. Please note! The recall notice is lacking significant details. Make sure you read, understand and print this prior to scheduling your work. If you suspect any leakage of brake fluid it is super important to understand the letter referenced above!

10/13/09 - RECALL OF DEAC SWITCH ANNOUNCED! Recall is for Problem #1

10/15/09 - More recall details added. Print the next two links, read, understand and bring them with you. This is all they should be expected to do for free.

Link to NHTSA Investigation including RECALL details and Remedy

Link to Detailed FORD Recall Document, Read this, understand this and bring it with you.

Ford Information Link -- Pretty Useless.

Ford Recall Notice to Owners. The only good statement in here is to park your van outside! Most everything else is company friendly and lacks the details and specific instructions to aid in proper diagnosis of the issue at hand.

Key information from NHTSA recall page

"Remedy: FORD WILL NOTIFY OWNERS AND DEALERS WILL INSTALL A FUSED WIRING HARNESS FOR THE SCDS. DEALERS WILL ALSO INSPECT THE ABS CONTROL CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR ABOUT OCTOBER 26, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751."

A SPECIAL Thank you to my representative Peter Welch of Vermont for his kick start!

RECALL FAQ, I will post as I learn more. (READ THIS!)

• Recall is official
• Recall is two part. 1. Fuse link must be installed and the SCDS must be inspected and possibly replaced. IF IT IS LEAKING! (See the FORD document above) 2. ECM/ABS connector must me taken apart and inspected and remedied.
• Does the recall include the ABS/ECM? -- Yes, only if your SCDS leaked will the connector be looked at. Well at the very least the ABS ECM connector should be inspected and cleaned, I suggest attaching a clip tie around the ABS/ECM connector. Ask the service manager to return that tie to you in one piece, this will verify they have taken the connector apart. If the manager cannot do that, report the issue.
• If your ECM/ABS unit was not damaged by fire or fluid it is highly unlikely it will be replaced by Ford.
• If your lights are still on after the recall and you are satified with the service as stated, contact the NHTSA ASAP and be prepared to wait again. (Problem #2 below and that has not been investigated or recalled.)

My Own Two Cents - because I paid for the website - Paradise by our dashboard light.

Well my fellow Windstar owners we got a recall. This is fantastic. It is also NOT the end of this problem. AN UNATTENDED FIRE CAN STILL HAPPEN. If Ford does not replace your SCDS switch because it was NOT leaking, be vigilant, watch it, it may start leaking, and if it does have them replace it ASAP! This should be part of an annual personal inspection. The recall solution fusable link DOES NOT STOP leaked fluid from traveling down the wires to the ABS UNIT where two high power 40A circuits are connected. If the fluid hits these circuits a FIRE will happen just like it did in my Windstar van. Listen to the advice of the NHTSA big guy and watch out for all of the warning signs including non-working cruise-control systems, non-working brake lights, illuminated brake-light and ABS dashboard (lights) symbols, and the inability to get the vehicle's transmission out of "park.", blown #10 fuse.

The NHTSA did an excellent job, they investigated the issue found and reported the problem to Ford, who issued the fastest possible company friendly solution. A consumer friendly soultion would have taken MUCH longer, so lets be happy with what we got. What did we get? You got the best document above, a document on Ford letter head that states in my own words, there is a link between the SCDS (speed control deactivation switch) and the ABS unit in which the SCDS can damage the ABS unit.

I have never asked for any donations but if you feel this website helped and saved you a ton of time. Please donate anything you want with your credit card to the American Cancer Society in honor of http://www.fordwindstarrecall.info it will give you a warm fuzzy inside. You can send an ACS honoree card when donating, if you want to send it to fordwindstarrecall.info,% Scott Malinowski, 518 Sugar Maple Lane, Bennington, VT 05201.

From the News Desk:

5/6/08 - Major increase in site volume for April! March was 6765 hits, April 12,326!

5/7/08- It appears the NHTSA is staring an investigation into the Deactivation switch leaking a causing fires! This is certainly good news and I'm sure will save lives. If you have a old deactivation switch that leaked, please do not throw it away, we may need to collect a few! I can be reached at scott (at) fordwindstarrecall (dot) info.

5/19/08 - Investigation Official - NHTSA Opened Investigation

11/22/08 - Some good/not so good news. According to my NHTSA contact, the NHTSA has "BURNED UP" three Windstars in its testing! They are still collecting more evidence and documentation, so please keep your reports to the NHTSA coming. TAKE ACTION now, report any problems to the NHTSA and remove the fuses and connectors as described in problem #1 below.

11/22/08 - Request to this page PEAKED in JULY this year 2008 at 42,380 requests! Proving the point that leaked warm brake fluid flows better than colder fluid.

2/20/09 - Evidence still being collected by NHTSA. They are going thru their database I received a call the other day. From what I am hearing they have a good case for a recall. As expected a quiet winter for new reports. This is likely due to the higher viscosity level of the brake fluid.

5/1/09 - No recall yet, more fires and more problems have been reported this time this year than this time last year and there is a significant general trend upward in cases. Added a Fire Prevention section.

5/18/09 - The NHTSA is working with Ford and still taking reports! Please do not give up, if you have any of the problems below, please report them.

8/18/09 - The NHTSA is expected to wrap up its investigation of this issue by the first week in October. While they cannot say definatively, a recall is widely expected.

10/2/09 - The case is NOT closed nor has a recall been announced. Ford has redesigned and is selling a new replacement part (HINT).

1/29/2010 - Posted a page for codes P0171, P0174 and P0401 common problems and solutions.

The List of Problems you might encounter including FIRE

• Loss of Brake Fluid (Problem # 1)
• Burning Smell or Smoke (Problem # 1)
• Melted Brake Deactivation Switch (SCDS) (Problem # 1)
• Brake light on after brake service. (We think this back pressure breaks the deac switch) (Problem # 1)
• Brake Light (Red) (Problem # 1 or Problem # 2)
• 15 amp Fuse #10 blowing out (Problem # 1)
• Fire or Smoke coming from under the van ABS ECM area while off. (Problem # 1)
• Melted ABS ECM wiring connector. (Problem # 1)
• Speedometer and Odometer Stop Working. (Problem # 1)
• Cruise control will not activate or deactivates without warning. (Problem # 1)
• ABS brake light (yellow) (Problem # 2 or Problem # 1)
• Ford Trouble code c1185. (Problem # 2 or Problem # 1)
• Brakes turn on squeel without warning. (Problem # 2)
• Problem codes P0171, P0174, P0401 171,174,401, EGR or System too Lean Issue (Other Problems)

To avoid a fire you should perform the following on your vehicle. - RECALL OBSOLETE

• Remove the Brake Deactivation Switch and replace it with a plug, install a jumper wire so the cruise will still work. The switch is located on the bottom side of the Master Cylinder. (This will prevent any more brake fluid from leaking into fire causing areas. That switch has also been the source of many fires. (I have seen pictures.) Save the old switch in a ziplock bag, the NHTSA may want it. (Total cost .25 hrs labor, $1.50 in parts) (no more than $50.00)
• Inspect the ABS brake module for leaked brake fluid that "wicked" down the wires from the deactivation switch. The ABS brake module is located under the vehicle in the area of the drivers seat. If it is corrupted it will look like the one below (notice the wetness where the connector comes together.) If it has wetness. this connector should be removed and cleaned with brake cleaner. (.5 hrs at most (about $50.00)
• Remove fuses 1 and 2 next to the battery (especially if you have Problem #2 or you had leakage.) This will make you ABS and Brake light stay on all the time.

Common questions

• Will doing the above make my van unsafe? Answer: Once done it will decrease the possibility of an unattended fire. It will only have normal brakes (which 99.999% of the time is just fine, the other .001% depends on your skill as a driver, like sliding on ice.)

Problem #1 (Skip to Problem #2)

The Brake Pressure Differential Deactivation Switch (SCDS) (2B264) located under the Master Cylinder (Behind the Air Filter) over time develops a leak. This causes a short and a fuse trip, fuse #10 if the engine is on. This leak also causes brake fluid to wick down two wires to the ABS brake module (2C219). The fluid accumulates on the (always on) power connectors for the ABS brake system which are powered by fuses 101 and 102 and are both 40 amp. The fluid attacts moisture, road salt and leads to a fire when the fluid and moisture act as conductor between the hot leads and ground. This switch has been the subject of other Ford Recalls, just not the Windstar van yet. Below is a picture of the switch in question. Notice the fluid that leaked on the part below it. This switch will cause cruise control problems, speedometer, odometer and ABS brake system problems.

The leaky switch at worst causes a fire at the point where it connects to the ABS ECM module. A picture of a connector that was subject to such a fire is located below. Notice the fluid all over the wires, and the melted copper wire and plastic harness cover.

What you need to do

• Report your issue to the NHTSA.GOV. (National Highway Transportation Safety Administration). Use this link. or call 1-800-327-4326.
• Get under your van and look for the connector directly under the drivers seat and above a cover. Look for a sticker that says Ford Kelsey-Hayes on it. Look for the wires. If it looks like the one below (see the leaked fluid where the wires are?) take action. First by reporting your issue above to the NHTSA. Then bring your vehicle to a TRUSTED mechanic or a Ford Dealership, you will pay to fix the problem but save your receipts, in case of a future recall. OR take the action below.

LEAKED SCDS AFFECTED ABS ECM UNIT BELOW

• Remove the two 40A fuses 101 and 102 located next to the battery under the hood. (See below). This will disable your ABS Brake System, and turn on the two brake lights on the dashboard.

• Inspect and Remove the connector from the Brake Pressure Deactivtion Switch. If there is leaked fluid remove the two fuses above. Remove this connector by locating the master cylinder under the hood of the car behind the big air hose on the right side.. There is are two wires extending from a connector attached to the bottom of the master cylinder. Pinch the two small ends of the connector and pull down.

SCDS connector pictured below (Loaded with fluid)

• Install a jumper in the connector (like a small piece of paper clip) tape it up well with electrical tape and secure the connector somewhere.

The above will deactivate your ABS system and prevent the leaked fluid from mixing with the two 40 amp ABS circuits which leads to fire. It will also by installing the jumper wire as described allow the cruise control to still work. You may need to replace fuse #10 if it broke, that will reactivate your cruise, speedometer and odometer. Failure to do the above steps before replacing fuse #10 could result in a catastrophic fire.

Problem #2 - ABS ECM Failure - ABS Brake Light.

The issue of the the ABS brake light is critical in that the ABS brake system does not function as designed by Ford. The issue is caused by HEAT in the ABS (Anti-Lock Brake System) ECM (Electronic Control Module) (2C219) module causing expansion of a large aluminum plate (heat sink) in the ECM which is attached to the ECM main circuit board at all points. The expansion occurs when the unit gets warm especially in the summer months and causes intermittent electrical connection in the unit because the fragile board is being stretched and malformed. The code most commonly scanned by professional mechanics is code c1185. Seen by us owners as a Yellow ABS Brake Light.

The picture below indicates how well attached/glued the aluminum board was the to circuit board. So well, that when removed the top layer of the board came with it.

Below are two pictures the one of the left was a mesurement of the board after it was in my freezer all night (same as your car parked outside in the winter), the one on the right was after I heated the board. There is at least a .25 mm difference in length! Obviously when this aluminum plate it attached to the board the way it is it will expand the board too. Making for BAD connections on the board when HOT.

Here is an excel snip-it to prove the expansion issue. a 4-1/2 Aluminum plate with 250 degrees of temp difference will expand .312108 mm! That is alot with a fragile circuit board!

What to DO

REPORT the problem to the NHTSA.GOV

There are two solutions.

• Replace the ECM unit and wait for it to happen again at your expense, so save your receipts. Always buy Ford parts if there is a chance you will be reimbursed. Also a Ford dealership may be the way to go here.

• Deactivate the ECM high power by removing fuses 101 and 102 so that the ABS is always off and not intermittent. And wait for Ford to listen to us thru your report to the NHTSA.GOV

Buying Parts?

The best OEM part prices found were art ford-parts.com. It was taken over by Titus-Will, here is a link to the parts. Please remove the ones you do not need.

1995/2003 : SW-6351 SWITCH (2B264) - Brake Pressure Deactivation Switch

NO TRACTION CONTROL

1999/2000 : XF2Z-2C219-AB - ECM Control Module

2001/2003 : 2F2Z-2C219-BA - ECM Control Module

TRACTION CONTROL

1999/2000 : XF2Z-2C219-BA - ECM Control Module w/Traction Control

2001/2005 : 2F2Z-2C219-CA - ECM Control Module w/Traction Control

Buy Parts Here

Discussion

Feel inclined to discuss the issue? Have a question. Go to http://www.2carpros.com/forum/5-vt49767.html.

A Picture is worth 1000 words, in this case 60,000 words.

If you are happy without ABS and can live without it consider the reverse procedure in any service manual to fix a dashboard lightbulb. ABS systems are not part of any state inspection I am aware of.

This page was generated by 2002 Ford Windstar owner Scott Malinowski, he can be reached at scott (at) fordwindstarrecall (dot) info