Ford Recalling 8.2 Million Vehicles To Replace Switches

Ford Motor Co. is recalling about 7.9 million cars, minivans and pickups in the United States with the same type of ignition switch that has caught fire in hundreds of vehicles. It is the second-largest recall in U.S. history.

The No. 2 automaker also is expanding its Canadian recall of vehicles with the switches from the 248,000 announced late last year to a total of 859,000 to match the makes and models being fixed in the United States.

That brings the total recall number to about 8.7 million vehicles - the largest recall by a single automaker. The largest recall occurred last year when 10 automakers had to fix seat belts in 8.8 million cars because of concerns the buckles sometimes failed to latch or unlatch.

The total cost of the Ford recall is expected to exceed $200 million, Ford sources said, speaking on condition of anonymity.

The ignition-switch problem was under intense scrutiny by the National Highway Traffic Safety Administration because consumers had reported about 820 fires started by the switches.

Some of the cases included reports of fire even when the vehicles were parked and shut off, according to documents on file at the highway safety administration. No injuries have been reported in the United States.

The first Canadian recall followed 260 reports of fire or smoke from ignition switches, causing minor injuries to three people.

The highway safety administration had been investigating 23.5 million Ford vehicles in the United States with the same type of ignition switch. However, some cars with the switch have had no or few reports of fires - for instance, the 1984-87 Lincoln Continental and Lynx.

Ford spokeswoman Francine Romine said the problem was a supplier’s change of putting less space between switch terminals, creating the potential for a short circuit and fire. That problem was limited to about one-third of the vehicles, she said.

NHTSA administrator Ricardo Martinez applauded Ford for “stepping forward to do a full safety recall before our investigation was completed.”

Recalls in both countries now cover: 1988-90 Escorts; 1988-92 and some early 1993 Mustangs, Thunderbirds, Tempos and Mercury Cougars and Topazes; 1988-89 Crown Victorias and Mercury Grand Marquises; 1988-89 Lincoln Town Cars; 1988-91 Aerostar minivans; 1988-91 Bronco sport-utility vehicles and F-series pickups; and 1988 EXPs.