NHTSA Investigation
RQ04003
HYDRAULIC BRAKE LINE FAILURE
Key Takeaways
- Investigation RQ04003 currently maps to 2 tracked vehicle-year pages across 1 make.
- This page summarizes the public investigation subject, status, timing, and affected tracked vehicles linked from NHTSA source data.
- The linked component on this record is service brakes, hydraulic:fluid.
What This Investigation Page Shows
This page summarizes a public NHTSA investigation record tied to one or more tracked vehicle-year pages in our database. Investigation records sit between owner complaints and recall campaigns: they can remain open, close without a recall, or connect to a later remedy action. Use this page to see which tracked vehicles are linked to the record, then open the individual vehicle pages for complaints, recalls, and crash test context.
Investigation Summary
ON APRIL 4, 2002, FORD MOTOR COMPANY NOTIFIED ODI OF A DEFECT CONDITION THAT COULD RESULT IN EXTENDED STOPPING DISTANCES IN APPROXIMATELY 250 THOUSAND MODEL YEAR (MY) 1995 AND 1996 WINDSTAR MINIVANS SOLD OR REGISTERED IN SALT BELT STATES (RECALL 02V-101).ACCORDING TO FORD, IMPROPER BRAKE LINE ROUTING IN VEHICLES MANUFACTURED AT THE OAKVILLE ASSEMBLY PLANT FROM JANUARY 14, 1994 THROUGH MAY 21, 1996 RESULTED IN SOME VEHICLES WITH MIS-POSITIONED BRAKE LINES THAT COULD CONTACT A DASH PANEL INSULATOR.SUCH CONTACT COULD ABRADE THE BRAKE LINE PROTECTION COATING AND RESULT IN CORROSIVE FAILURE OF THE BRAKE LINES. ODI OPENED RQ04-003 TO INVESTIGATE COMPLAINTS OF BRAKE LINE FAILURE IN WINDSTAR VEHICLES THAT WERE:(1) LOCATED OUTSIDE THE RECALL REGION; OR (2) BUILT AFTER THE RECALL RANGE.REGARDING THE LATTER GROUP, FORD CHANGED THE ASSEMBLY PROCESS AFTER MAY 21, 1996 TO ELIMINATE THE MIS-BUILD PROBLEM.THE FAILURE RATES IN THE MY 1996 WINDSTAR VEHICLES BUILT AFTER THE PROCESS CHANGE ARE RELATIVELY LOW IN BOTH THE SALT-BELT STATES. WITH RESPECT TO THE MY 1995 AND 1996 VEHICLES BUILT DURING THE PERIOD OF CONCERN THAT WERE NOT SOLD OR REGISTERED IN SALT BELT STATES, THE FAILURE RATE IS ALSO LOW.THE RELATED BRAKE LINE WARRANTY CLAIM RATE FOR THOSE VEHICLES IS ALSO LOW. ACCORDINGLY, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED IN THE MY 1995-96 WINDSTAR VEHICLES THAT WERE NOT INCLUDED IN RECALL 02V-101.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Manufacturer listed on the source record: Ford Motor Company
Component listed on the source record: SERVICE BRAKES, HYDRAULIC:FLUID
Affected Vehicles (2)
Browse Affected Vehicles
Affected Models
All data is sourced from NHTSA public records. This site is not affiliated with, endorsed by, or operated by the National Highway Traffic Safety Administration or any government agency. Complaints are unverified consumer reports submitted to NHTSA and may not reflect confirmed defects. For official information, visit nhtsa.gov.
Data synced from NHTSA on May 4, 2026