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Feds open investigation into Chevy Express, Ford Freestar rust issues

'Tis the season... for road salt. And with that, comes rust. And what does rust bring? Well, for Ford and General Motors, a National Highway Traffic Safety Administration investigation. According to The Detroit News, NHTSA is looking into potential recalls issues with Chevrolet Express vans and Ford Freestar minivans.
The feds have received five complaints that rust has caused leaking fuel filler pipes on 2003 Express vans. Separately, seven complaints have been filed over excessive rust in the rear wheel wells of 2004 Ford Freestar and Mercury Monterey minivans. The Freestar and Monterey went out of production in 2007. Neither issue has resulted in any crashes or injuries, according to the report.

NHTSA advances investigation of Ford Crown Victoria headlights

The National Highway Traffic Safety Administration is opening a preliminary evaluation into reports of suddenly failing headlights on 517,945 examples of the 2003-2005 Ford Crown Victoria and Mercury Grand Marquis. The government started looking into this problem in April when the North Carolina Consumers Council filed a defect petition with the agency. Now, the inquiry has moved to the next step. According to NHTSA's documentation (as a PDF), it examined its own database and worked with Ford to come up with a total of 3,609 complaints of the front lighting control module suddenly failing. When this happens, drivers lose the low-beam headlights, but the high-beams can be used by holding the stalk. Sometimes turning the switch off and on fixes the issue. Additionally, there are 15 allegations of crashes, and one reported shoulder injury. NHTSA's preliminary evaluations "evaluate the scope, frequency, and consequence of the alleged defect" and don't necessarily lead to a recall. NHTSA looked into this problem once before in 2008 and 2009 and decided that a recall wasn't necessary. Ford also extended the warranty on the front lighting control module for these vehicles. INVESTIGATION Subject : Loss of headlights Date Investigation Opened: AUG 10, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15028 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: After receiving a defect petition (DP15002) concerning the loss of headlights and other exterior lighting in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles, the Office of Defects Investigation (ODI) analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure. The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066). Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off. In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.

Ford announces two recalls, 442k vehicles affected in North America

Ford is announcing two recalls for North American that affect a total of 442,300 vehicles and multiple model lines. The larger campaign covers the possibility of electric power steering systems that can fail in the 2011-2013 Ford Flex, Taurus, Lincoln MKS, and MKT; the 2011-2012 Ford Fusion and Lincoln MKZ; and the 2011 Mercury Milan. This recall affects 422,814 vehicles in North America, including 393,622 in the United States, 25,195 in Canada, and 3,997 in Mexico. According to the company, an intermittent electrical connection can cause the power steering to cut out, although manual steering would still work. Ford knows of four minor accidents from this issue, but there are no injuries. Depending on trouble codes from the vehicle, dealers will either upgrade software for the power steering control module or replace the steering gear. The second recall covers 19,486 examples of the 2015 Ford Mustang with the 2.3-liter EcoBoost turbocharged four-cylinder engine with a production date between February 14, 2014, and February 10, 2015 at the Flat Rock Assembly Plant. Specifically, there are 19,095 of these in the US and 391 in Canada. These pony cars can show elevated underbody temperatures, which can lead to degradation of the fuel tank, fuel vapor lines, and parking brake cable seals. There are no reports of accidents, injuries or fires from this, though. To fix things, dealers will install a better-insulated fuel tank shield, add thermal patches around the tank and parking brake cable, and put thermal wraps around the fuel vapor lines. You can read the specific build dates and locations for the models affected by the power steering issue in Ford's press release below the video. Related Video: FORD ISSUES TWO SAFETY RECALLS IN NORTH AMERICA DEARBORN, Mich., May 27, 2015 – Ford is issuing two safety recalls in North America. Four minor accidents and no injuries are attributed to one of these conditions.