1 9 9 8 -2 0 0 3 Ford W indstar 1 9 9 8 2 0 0 3 Ford W indstar - - PowerPoint PPT Presentation

▶
1 9 9 8 2 0 0 3 ford w indstar 1 9 9 8 2 0 0 3 ford w
SMART_READER_LITE
LIVE PREVIEW

1 9 9 8 -2 0 0 3 Ford W indstar 1 9 9 8 2 0 0 3 Ford W indstar - - PowerPoint PPT Presentation

Jul 19, 2023 408 likes •969 views

1 9 9 8 -2 0 0 3 Ford W indstar 1 9 9 8 2 0 0 3 Ford W indstar Rear Axle Beam C Corrosion Failure i F il W ebEx Presentation to Ford Safety Office PE1 0 -0 1 6 0 7 / 2 1 / 2 0 1 0 1 1998-2003 Ford Windstar Rear Axle B Beam Corrosion

slide-1
SLIDE 1

1 9 9 8 -2 0 0 3 Ford W indstar 1 9 9 8 2 0 0 3 Ford W indstar Rear Axle Beam C i F il Corrosion Failure

W ebEx Presentation to Ford Safety Office 0 7 / 2 1 / 2 0 1 0 PE1 0 -0 1 6

1

slide-2
SLIDE 2

1998-2003 Ford Windstar Rear Axle B C i F il Beam Corrosion Failure

Th t t hi l d b ti l h i f th The 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”

2

releasing the rear axle fork plate .

slide-3
SLIDE 3

http://trcpg.com/facilitydynamics.asp Intended path on test track 3

slide-4
SLIDE 4

Removed axle to modify for testing 4

slide-5
SLIDE 5

VRTC fork plate Two of the dowel pins were drilled and fitted with spring-loaded plastic cotter pins plastic cotter pins 5

slide-6
SLIDE 6

Release mechanism and test setup as viewed from rear of vehicle 6

slide-7
SLIDE 7

VRTC rear axle release system – initial weld pattern 7

slide-8
SLIDE 8

VRTC rear axle release system – final weld pattern 8

slide-9
SLIDE 9

Windstar and chase vehicle Freestar prior to test 9

slide-10
SLIDE 10

Contour HD 1080P cameras 10

slide-11
SLIDE 11

play video Windstar_Rear_Axle_Test-2010-07-08-FINAL.wmv 11

slide-12
SLIDE 12

Actual Windstar path from V-Box GPS data plotted in Google Earth 12

slide-13
SLIDE 13

View from chase vehicle camera 13

slide-14
SLIDE 14

View from chase vehicle camera 14

slide-15
SLIDE 15

View from panning camera 15

slide-16
SLIDE 16

View from underneath camera 16

slide-17
SLIDE 17

Post-test view of left front 17

slide-18
SLIDE 18

Post-test view of left rear 18

slide-19
SLIDE 19

Post-test view of left-rear wheel well 19

slide-20
SLIDE 20

Post-test view of right rear 20

slide-21
SLIDE 21

Post-test view of right-rear wheel well 21

slide-22
SLIDE 22

Post-test view of right-rear wheel from rear of vehicle 22

slide-23
SLIDE 23

Post-test view of right-rear wheel from front 23

slide-24
SLIDE 24

Post-test view of right front 24

slide-25
SLIDE 25

Post-test view from below rear axle 25

slide-26
SLIDE 26

Post-test close-up view of right-side axle against floor pan 26

slide-27
SLIDE 27

VOQs on the 1998-2003 Ford Windstar R A l B C i F il Rear 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

27

slide-28
SLIDE 28

VOQ 10334753 28

slide-29
SLIDE 29

VOQ 10327329 29

slide-30
SLIDE 30

VOQ 10327329 30

slide-31
SLIDE 31

VOQ 10331092 31

slide-32
SLIDE 32

VOQ 10331092 32

slide-33
SLIDE 33

VOQ 10331092 33

slide-34
SLIDE 34

The incident was 23 days and 2,291 miles after . . . 34

slide-35
SLIDE 35

VOQ 10331092 35

slide-36
SLIDE 36

Crash site along service roadway near freeway ramp 36

slide-37
SLIDE 37

Post-crash view of left front 37

slide-38
SLIDE 38

Post-test view of left rear 38

slide-39
SLIDE 39

Post-crash view of left-rear wheel well 39

slide-40
SLIDE 40

Post-crash view of left-rear wheel well 40

slide-41
SLIDE 41

Post-crash view of right rear 41

slide-42
SLIDE 42

Post-crash view of right-rear wheel well 42

Laboratory and cell-phone videos of key turn speed

slide-43
SLIDE 43

Post-crash view of right front 43

slide-44
SLIDE 44

Post-crash view underneath vehicle 44

slide-45
SLIDE 45

Post-crash view underneath vehicle 45

slide-46
SLIDE 46

Post-crash view underneath vehicle showing axle fracture 46

slide-47
SLIDE 47

Crash site along service roadway near freeway ramp 47

slide-48
SLIDE 48

Crash site along service roadway near freeway ramp 48

slide-49
SLIDE 49

Crash site along service roadway near freeway ramp 49

slide-50
SLIDE 50

Crash site along service roadway near freeway ramp 50

slide-51
SLIDE 51

Crash site along service roadway near freeway ramp 51

slide-52
SLIDE 52

Post-crash view of right front 52

slide-53
SLIDE 53

Discussion

53

slide-54
SLIDE 54

For more information contact:

Daniel Pearse T t ti S f t E i Transportation Safety Engineer United States Department of Transportation National Highway Traffic Safety Administration Vehicle Research and Test Center Vehicle Research and Test Center Defects Analysis Group Post Office Box B37 10820 State Route 347 10820 State Route 347 East Liberty, OH 43319-0337 937-666-4511 x267 dan.pearse@dot.gov

54