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.

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.

The List of Problems you might encounter

• 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 #1 (Skip to Problem #2)

The Brake Pressure Differential Deactivation Switch (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.

• 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.

• 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.

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