Ford Recalls 4.5 Million Vehicles

A faulty switch linked to fires in Ford vehicles is blamed for another round of recalls that has pushed the total affected registered vehicles to 14.3 million - the largest cumulative recall ever for one problem.

The latest recall is for 4.5 million vehicles with cruise control deactivation switches that have been blamed for fires. The federal government added another 2 million vehicles to the total after they factored in some no longer thought to be in use. The half-dozen recalls involving switches made by Texas Instruments started a decade ago.

Ford stopped using the switches in 2003. Texas Instrument blamed a business unit no longer operating for creating them. The company said they were made to “meet and exceed” Ford specifications.

The automaker recalled the 1.1 million Windstar minivans made 1995 through 2003. In addition, it included models not covered in earlier recalls although the switches in those vehicles weren’t found to be unsafe.

In a letter to the National Highway Traffic Safety Administration, Ford officials said an increasing number of Ford Winstars had the leakage problem, with some fires reported. They also wrote that the company did not know of any accidents or injuries stemming from the fires.

A 2006 investigation by the federal agency, according to Texas Instruments, concluded there was more than one cause of the fires. However, in 2008 the agency discovered the potential for fire occurred when the switches leaked internally and overheated. The agency revealed four reports of fires after leaking fluid damaged antilock brake control modules, which are electrically charged.

Vehicles without cruise control also are included in the recall due to their having switches through which brake fluid flows. However, a letter from automaker said, “Ford is taking this action on all of these vehicles to address possible ongoing customer lack of confidence in vehicles with the affected switch.”

Ford suggests owners of the recalled vehicles park them outside until they receive instructions about how to get needed repairs. To fix the switches, a harness will be installed to keep fluid from going anywhere it could catch fire.

The recall includes: 1995-2003 Ford Windstar; 2000-2003 Ford Excursion diesel; 1993-1997 and 1999-2003 Ford F-Super Duty diesel; 1992-2003 Ford Econoline; 1995-2002 Ford Explorer; 1995-2002 Mercury Mountaineer; 1995-1997 and 2001-2003 Ford Ranger; and 1994 Ford F35 Motorhome vehicles.

Earlier recalls included such popular Ford brands as the F-series of pickup trucks. There have been hundreds of complaints and dozens of lawsuits due to fires blamed on faulty switches. There also have been reports of a small number of injuries, although none reported in relation to the new recall.

At the end of September, Toyota Motor Corp announced a recall of about 3.8 million vehicles on roads in the United States because the floor mats can get loose and force down the accelerator. Five deaths in wrecks have been linked to the problem.