Chamberlan v. Ford Motor Co.

369 F. Supp. 2d 1138, 2005 U.S. Dist. LEXIS 10042, 2005 WL 1155246
CourtDistrict Court, N.D. California
DecidedMay 4, 2005
DocketC 03-02628 CW
StatusPublished
Cited by34 cases

This text of 369 F. Supp. 2d 1138 (Chamberlan v. Ford Motor Co.) is published on Counsel Stack Legal Research, covering District Court, N.D. California primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Chamberlan v. Ford Motor Co., 369 F. Supp. 2d 1138, 2005 U.S. Dist. LEXIS 10042, 2005 WL 1155246 (N.D. Cal. 2005).

Opinion

ORDER GRANTING IN PART AND DENYING IN PART DEFENDANT’S MOTION FOR SUMMARY JUDGMENT AND GRANTING DEFENDANT’S MOTION FOR PARTIAL JUDGMENT ON THE PLEADINGS

WILKEN, District Judge.

Defendant Ford Motor Company moves for summary adjudication of all claims brought by Plaintiffs Susan Chamberlan and Henry Fok, on behalf of themselves and others similarly situated (collectively, Plaintiffs). In the alternative, Defendant seeks summary adjudication of the claims of certain subsets of the class. Defendant also moves for judgment on the pleadings of Plaintiffs’ UCL claims on behalf of the general public. Plaintiffs oppose these motions. 1

*1141 The matters were heard on March 18, 2004. Having considered all of the papers filed by the parties and oral argument on the motion, the Court grants in part and denies in part Defendant’s motion for summary adjudication, and grants Defendant’s motion for partial judgment on the pleadings.

BACKGROUND

Plaintiffs bring this action on behalf of themselves and all similarly situated persons residing in California who purchased certain automobiles manufactured by Defendant. 2 Plaintiffs allege that, beginning in 1996, Defendant concealed material information about the intake manifolds in these cars, in violation of California law.

An intake manifold performs multiple functions in a automobile engine. The intake manifold distributes air to each of the engine’s cylinders. The intake manifold may also serve as part of the cooling system by channeling coolant across the engine, to and from the radiator. Historically, intake manifolds have been made of aluminum or other metal. Aluminum manifolds can be expected to last the life of the engine. Defendant had no problems with the performance of the water crossover portions that distribute coolant in its aluminum manifolds. Solomon Deck, Ex. 3, Beatham Dep. 11:8-12.

The manifolds at issue in this case are composed entirely of a non-metal nylon and glass composite material, i.e. plastic. Defendant’s first such manifold was described by Ford employees as “the world’s first V8 composite intake, and the first composite intake manifold to integrate a water crossover.” Solomon Decl. Ex. 8, 4.6L-2v Composite Intake Action Plan & Lessons Learned, February 17, 1999, at 2. The composite manifold was hailed as “the beginning of a major technology shift toward the use of plastics & composites on core' engine applications yielding substantial cost, and weight savings.” Id.

Defendant began using non-metal composite manifolds, with a thickness of three millimeters, in the water crossover pieces in 1996 model year vehicles, which were first available for sale in June, 1995. Plaintiffs’ earliest evidence that Defendant was aware of problems with the manifolds is a November 16, 1995 report that a taxicab and a police car (heavily used cars referred to as “fleet” vehicles) were experiencing coolant leaks. Solomon Deck Ex. 5, Nov. 16, 1995 Concern Detail at 1. Ford employee Gerald Czadzeck assigned engineer Wolfgang Beatham to evaluate the results of a material analysis and bench test fatigue simulation. By June 6, 1996, Mr. Beatham estimated the part’s failure rate to be as high as nineteen per thousand at 50,000 miles and 270 per thousand at 120,000 miles. Id. at 3. This estimate did not reflect actual repair rates but rather was “something we expect to occur at higher mileage with the current production intake manifold.” Id. at 5. According to Mr. Czadzeck, Mr. Beatham’s estimates reflected the “potential risk of not correcting the problem” as “extrapolated to the general public” rather than just high-end fleet users. Solomon Deck, Ex. 4, Czad-zeck Dep. 61:21-62:5. Mr. Czadzeck characterized Mr. Beatham’s estimates as “tremendously high failure rates.” Id. 62:7-9. By August 28, 1997, internal Ford documents described both a “high number of *1142 wear out failures on the composite intake manifold on fleet customers and an increasing number of concerns on general population vehicles.” Solomon Decl. Ex. 12, Field Failures of Manifold Incorporated Engine Coolant Crossover Duct at 1.

Between 1996 and 2000, Defendant tried to fix the problem by making several changes to the design of the non-metal manifolds. The first proposed solution was to add one millimeter of thickness to the water crossover parts; bench and finite element testing reportedly showed that this would reduce the projected warranty liability to zero at 120,000 miles. Id. at 3. This four millimeter “second generation” water crossover design was sold in 1997 model year vehicles. For 1998 model year vehicles’ third generation manifold design, Defendant increased the thickness to five millimeters. Solomon Decl. Ex. 2, Riedel Dep. 31:7-11. According to Ford documents, the “4 and 5 mm iterations each demonstrated significant improvements in durability, but neither met [Defendant’s] 95 percentile customer durability requirements.” Composite Intake Action Plan & Lessons Learned, February 17, 1999, at 2. Defendant later changed the nylon material “slightly” and made some design revisions after the third generation. Riedel Dep. 33:5-17.

In December, 1997, in order to address field failures with the three millimeter coolant crossover, Defendant issued Owner Notification Programs (ONPs) to replace manifolds on Crown Victoria police vehicles, and extended warranties on Crown Victoria taxi, Thunderbird/Cougar and Mustang vehicles. Solomon Decl., Ex. 13, Field Failures of Intake Manifold Incorporated Engine Coolant Crossover Duct, July 27, 2000, rev. April 5, 2001, at 1. Similar ONPs were issued for four millimeter manifolds on fleet vehicles and some missed three millimeter vehicles. Id. These ONPs provided five millimeter replacements for ear owners’ three and four millimeter manifolds. Id.

Defendant ultimately decided not to use all-plastic crossover designs in future vehicles. Id. at 5. The Ford team had agreed,

[D]ue to the fact that our best evidence indicates that the failure is due to the accumulated effects of time, temperature and pressure in service; there is no reason to believe that the demand for service parts will increase linearly or flatten out. In the lower severity duty cycles the vehicles built at or around job # 1 are only now approaching the mileages where failures have occurred in the most severe fleet applications. In all probability the light duty applications will continue to fail at ever increasing rates ....

Solomon Decl. Ex. 17, June 29, 2000 Email from Gary Liimatta to Thomas Zahm. According to an October 20, 2000 email, approximately 8,000 intake manifolds were being replaced each month on 1996 to 2000 model year 4.6L-2v passenger cars. Solomon Decl. Ex. 15, October 20, 2000 Email from Gregory Banish to Thomas Zahm. Defendant never issued ONPs to members of the Plaintiff class.

Plaintiffs also provide evidence that class members were affected by Defendant’s failure to alert them to problems with their manifolds.

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Bluebook (online)
369 F. Supp. 2d 1138, 2005 U.S. Dist. LEXIS 10042, 2005 WL 1155246, Counsel Stack Legal Research, https://law.counselstack.com/opinion/chamberlan-v-ford-motor-co-cand-2005.