1998-2003 ford windstar rear axle beam l i fcic orrosion ... presentation 7... · 1998-2003 ford...
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1998-2003 Ford Windstar 1998 2003 Ford Windstar Rear Axle Beam
C i F ilCorrosion Failure
WebEx Presentation to Ford Safety Office 07/21/2010PE10-016
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1998-2003 Ford Windstar Rear Axle B C i F ilBeam Corrosion Failure
Th t t hi l d b ti l h i f thThe test vehicle was prepared by creating a release mechanism for the
rear axle, installing two five-point harnesses, a V-Box III data
collection system, and titanium outriggers. The front outrigger was
set at 12 inches and the rear outrigger was set at 14 inches (puck
clearance to ground). The test was conducted on the Vehicle
Dynamics Area (VDA) at TRCPG by accelerating to 35 mph in a y ( ) y g p
straight line and intercepting a 300-ft radius circle course, then
releasing the rear axle “fork plate”
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releasing the rear axle fork plate .
http://trcpg.com/facilitydynamics.asp Intended path on test track
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Removed axle to modify for testing
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VRTC fork plate
Two of the dowel pins were drilled and fitted with spring-loaded plastic cotter pinsplastic cotter pins
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Release mechanism and test setup as viewed from rear of vehicle
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VRTC rear axle release system – initial weld pattern
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VRTC rear axle release system – final weld pattern
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Windstar and chase vehicle Freestar prior to test
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Contour HD 1080P cameras
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play video Windstar_Rear_Axle_Test-2010-07-08-FINAL.wmv
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Actual Windstar path from V-Box GPS data plotted in Google Earth
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View from chase vehicle camera
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View from chase vehicle camera
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View from panning camera
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View from underneath camera
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Post-test view of left front
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Post-test view of left rear
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Post-test view of left-rear wheel well
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Post-test view of right rear
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Post-test view of right-rear wheel well
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Post-test view of right-rear wheel from rear of vehicle
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Post-test view of right-rear wheel from front
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Post-test view of right front
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Post-test view from below rear axle
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Post-test close-up view of right-side axle against floor pan
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VOQs on the 1998-2003 Ford Windstar R A l B C i F ilRear Axle Beam Corrosion Failures
473 VOQ l f il• 473 VOQs on rear axle failures
• 6 alleged crashes
• 2 alleged injuries
• Numerous loss of control incidents
• 1 rollover
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VOQ 10334753
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VOQ 10327329
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VOQ 10327329
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VOQ 10331092
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VOQ 10331092
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VOQ 10331092
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The incident was 23 days and 2,291 miles after . . .
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VOQ 10331092
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Crash site along service roadway near freeway ramp
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Post-crash view of left front
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Post-test view of left rear
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Post-crash view of left-rear wheel well
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Post-crash view of left-rear wheel well
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Post-crash view of right rear
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Post-crash view of right-rear wheel well
42Laboratory and cell-phone videos of key turn speed
Post-crash view of right front
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Post-crash view underneath vehicle
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Post-crash view underneath vehicle
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Post-crash view underneath vehicle showing axle fracture
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Crash site along service roadway near freeway ramp
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Crash site along service roadway near freeway ramp
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Crash site along service roadway near freeway ramp
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Crash site along service roadway near freeway ramp
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Crash site along service roadway near freeway ramp
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Post-crash view of right front
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Discussion
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For more information contact:
Daniel Pearse T t ti S f t E iTransportation Safety EngineerUnited States Department of TransportationNational Highway Traffic Safety AdministrationVehicle Research and Test CenterVehicle Research and Test CenterDefects Analysis Group Post Office Box B3710820 State Route 34710820 State Route 347East Liberty, OH 43319-0337 937-666-4511 [email protected]
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