2002 Ford Windstar
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Windstar › 2002
These records cover every 2002 Ford Windstar. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
9 recalls name the 2002 Ford Windstar. Newest first.
Ford Motor Company (Ford) is recalling certain model year 1998-2003 Windstar vehicles manufactured September 2, 1997, to July 3, 2003. The affected vehicles were previously remedied to safeguard against the rear axle cracking from corrosion, however, the remedy brackets may have been misinstalled. The incorrect bracket installations may limit the…
Risk and remedy
Risk
If the brackets were not installed properly, the rear axle may fracture, affecting the vehicle handling and increasing the risk of a crash.
Remedy
Ford will notify owners, and dealers will inspect the brackets to verify their proper installation. If a bracket is found to have been misinstalled, the rear axle will be replaced. These repairs will be performed free of charge. The began on October 21, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S27.
Ford IS recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997, through july 3, 2003, and currently registered or originally sold in virginia. Over time, corrosion can weaken the rear axle making it susceptible to torsional stress. corrosion and stress can lead to cracks which, if undetected, can increase and result…
Risk and remedy
Risk
A fractured axle can affect vehicle handling and increase the risk of a crash.
Remedy
Ford will notify owners, and dealers will inspect and install rear axle reinforcement brackets, or replace the axles, as necessary. this service will be performed free of charge. The recall began on june 19, 2012. owners may contact ford at 1-866-436-7332.
Ford IS recalling certain model year 1999-2003 windstar vehicles originally sold in or currently registered in the state of virginia. Corrosion-related fractures of the front lower control arm rear attaching brackets and body mount attachments may occur.
Risk and remedy
Risk
A separation of a front lower control arm rear attaching bracket may result in a lower control arm separation. a separation of both front subframe rear body mounts may result in separation of the steering intermediate shaft. either condition could result in significant loss of steering control, increasing the risk of a crash.
Remedy
Dealers will inspect both front lower control arm rear attaching brackets and both body mount attachments at the rear of the front subframe and make the necessary repairs free of charge. The recall began on june 18, 2012. owners may contact ford at 1-866-436-7332.
Ford IS recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997, through july 3, 2003, registered in puerto rico. due to increased stresses caused by high cycles of torsional loading, specific to this market, the rear axle can crack.
Risk and remedy
Risk
A fractured axle may result in a loss of vehicle control, increasing the risk of a crash.
Remedy
Ford will notify owners, and dealers will inspect and install a reinforcement bracket on the rear axle or replace the axles, as necessary. this service will be provided free of charge. the recall began on june 1, 2012. owners may contact the ford motor company customer relationship center at 1-866-436-7332.
Ford IS recalling certain model year 1999-2003 windstar vehicles originally sold in or currently registered in the states of connecticut, delaware, the district of columbia, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, utah, vermont…
Risk and remedy
Risk
This could result in reduced steering control increasing the risk of a crash.
Remedy
Dealers will inspect both front lower control arm rear attaching brackets, and both body mount attachments at the rear of the front subframe, and make the necessary repairs free of charge. If repairs cannot be made to a vehicle, ford will offer to repurchase the vehicle. The safety recall IS expected to begin on or before february 21, 2011. owners may contact ford at 1-866-436-7332.
Ford IS recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997 through february 28, 2003 and currently registered or originally sold in connecticut, delaware, district of columbia, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio…
Risk and remedy
Risk
A fractured axle can affect vehicle handling and increase the risk of a crash.
Remedy
As parts become available, dealers will inspect and if necessary install the rear axle reinforcement brackets free of charge. this service will be performed free of charge. the safety recall began on october 20, 2010. owners may contact ford at 1-866-436-7332.
Ford IS recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 F-250 sd through F-550 sd diesel, 1992-2003 E-150 through E-550, 1995-2002 explorer, 1997 and 2002 mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 F53 vehicles equipped with the texas instruments speed control deactivation switch (scds). the…
Risk and remedy
Risk
A vehicle fire could occur with or without the engine running.
Remedy
Ford will notify owners that dealers will install a fused wiring harness in line with the scds. on 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair as necessary. repairs will be completed free of charge. the safety recall began on october 27, 2009. owners may contact ford at 1-888-222-2751.
Certain aftermarket fuel filters sold under the purolator brand name, p/n f65277, shipped from january 16 through june 2, 2006, for use on the above listed passenger vehicles. due to incorrect design, the quick connectors may not fully seat with the tube interface, even though the person making the connection may believe that the quick connector IS fully…
Risk and remedy
Risk
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
Remedy
Ufi will notify owners and replace the filters free of charge. the recall began on august 4, 2006. owners may contact ufi filters USA at 800-230-5876.
Certain minivans fail to comply with the requirements of federal motor vehicle safety standard no. 225, "child restraint anchorage system." during testing, a third row bench floor-to-seat latch released before the strength requirement was met. identical latches are used in the second row of seats.
Risk and remedy
Risk
If the latches on TH4E second or third row seats of the vehicle release in a crash, the potential for occupant injury IS increased.
Remedy
Dealers will replace the seat-to-floor latches on the second and third row of seats. owner notification began on november 21, 2003. owners should contact ford at 1-800-392-3673.
Owner complaints
1,353 complaints45 involved a crash48 involved a fire53 injuries1 deaths
What owners report most
Latest complaints
- Structure › Frame and members · Suspension
The contact owns a 2002 Ford Windstar. The contact received notifications of NHTSA Campaign Numbers: 11V030000 (STRUCTURE) and 15V608000 (SUSPENSION). The contact stated that while approaching a traffic signal and driving slowly, the vehicle shook, and the engine shifted. The contact stated that…
The contact owns a 2002 Ford Windstar. The contact received notifications of NHTSA Campaign Numbers: 11V030000 (STRUCTURE) and 15V608000 (SUSPENSION). The contact stated that while approaching a traffic signal and driving slowly, the vehicle shook, and the engine shifted. The contact stated that the engine shifted to the right. In addition, the contact lost control of the steering wheel. The contact stated that the RPMs became elevated. The contact pulled over into a parking lot and turned off the vehicle. The contact exited the vehicle, and upon inspection, became aware that the subframe had detached and was dragging. The contact believed that the motor mounts were fractured. The vehicle was towed to a tow yard. The vehicle was not taken to the dealer or an independent mechanic, and the vehicle was not repaired. The vehicle remained at the tow yard unrepaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline to report the failure. The approximate failure mileage was 108,000.
- Structure › Body · Suspension
Axle broke on rt side just underneath the bracket that ford installed for recall.i was only going 10mph when it happened no warning I was able to gain control and stop was towed into a shop not driveable if this seems to be a problem mine looked fine they must filled it up with expand foam I would think that would trap in more moisture but these are dangerous they should all be fixed or bought back from the customer
- Electrical system · Engine · Vehicle speed control
Manufacture Recall # 09S09 NHTSA Recall # 09V399000 Instrument cluster has become faulty. Details listed below. Overdrive (O/D) light will randomly start flashing for no reason ABS will randomly engage Parking brake light will randomly turn on Speedometer with become sporadic Transmission has…
Manufacture Recall # 09S09 NHTSA Recall # 09V399000 Instrument cluster has become faulty. Details listed below. Overdrive (O/D) light will randomly start flashing for no reason ABS will randomly engage Parking brake light will randomly turn on Speedometer with become sporadic Transmission has trouble shifting gears due to tachometer becoming sporadic Vehicle will randomly try to die/stall out at a prolonged stop or while coming to a stop, even after all charging components have been replaces i.e. battery, alternator, drive belt, and cables.
- Unknown or other
The rear axle passenger side broke.
- Suspension
The contact owns a 2002 Ford Windstar. The contact stated that while driving at approximately 55 MPH, the contact pulled over and noticed that the tire was not straight inside the wheel well. While hoisting the vehicle on a lift at the residence, the contact noticed that the tire was rubbing on the…
The contact owns a 2002 Ford Windstar. The contact stated that while driving at approximately 55 MPH, the contact pulled over and noticed that the tire was not straight inside the wheel well. While hoisting the vehicle on a lift at the residence, the contact noticed that the tire was rubbing on the inside of the wheel well and that the rear axle had fractured. The contact stated that the failure occurred at the site of the repair on the patch. The vehicle was taken to an independent mechanic and was informed about a recall. The contact called the local dealer and was informed that the VIN was not under recall. The manufacturer was contacted, but no assistance was provided. The contact stated that the failure was related to NHTSA Campaign Number: 10V385000 (Suspension). The failure mileage was approximately 160,000.
- Engine
The contact owns a 2002 Ford Windstar. The contact stated while driving 60 MPH, the vehicle was wobbling uncontrollably and almost caused an accident. No warning light was illuminated. The vehicle was towed to an independent mechanic. The vehicle had been diagnosed by an independent mechanic. The…
The contact owns a 2002 Ford Windstar. The contact stated while driving 60 MPH, the vehicle was wobbling uncontrollably and almost caused an accident. No warning light was illuminated. The vehicle was towed to an independent mechanic. The vehicle had been diagnosed by an independent mechanic. The contact was informed that the rear axle needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure and provided no assistance. The failure mileage was approximately 142,000.
- Suspension
The contact owns a 2002 Ford Windstar. The contact stated while driving 40 MPH, there was an abnormal sound coming from the vehicle. The contact pulled over on the side of the road and had the vehicle towed. The vehicle was diagnosed, and the contact was informed that the rear driver’s side axle…
The contact owns a 2002 Ford Windstar. The contact stated while driving 40 MPH, there was an abnormal sound coming from the vehicle. The contact pulled over on the side of the road and had the vehicle towed. The vehicle was diagnosed, and the contact was informed that the rear driver’s side axle had fractured. The axle was replaced. On another occasion while driving 20 MPH over railroad tracks, the contact heard an abnormal sound coming from the vehicle. The contact parked the vehicle and noticed that the rear driver’s side axle had fractured. The vehicle was towed to the dealer who confirmed that the rear driver’s side axle had fractured and needed to be replaced. The vehicle was repaired. The manufacturer was contacted and stated that the vehicle was not under recall. The failure mileage was 139,619.
- Suspension · Unknown or other · Wheels
Rear Axle . Fell on the highway split in half while I was driving on a state Hwy 71 at 45 mph. Cracked rear axle. 2002 Ford Windstar part of a recall for Rear axle. No warning was given and didn't know about the recall until after it happened. Inspection was preformed by a mechanic. I could have flipped or rolled or caused a major collision as this highway is very heavily traveled.
- Suspension
The contact owns a 2002 Ford Windstar. The contact stated that while the vehicle was at an independent mechanic to replace the water pump, the mechanic determined that the rear axle was cracked and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure…
The contact owns a 2002 Ford Windstar. The contact stated that while the vehicle was at an independent mechanic to replace the water pump, the mechanic determined that the rear axle was cracked and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the previous owner had the vehicle serviced under NHTSA Campaign Number: 10V385000 (Suspension). The failure mileage was approximately 116,000.
- Structure › Body
The van took off without my control and the brakes stopped working and the fuel system it caused me to have two accidents within a week of each other
- Power train › Axle assembly · Suspension
The contact owns a 2002 Ford Windstar. The contact stated that while driving approximately 30 MPH, there was an abnormally loud sound coming from the rear of the vehicle. The contact lost control of the vehicle and drove off the side of the roadway. The vehicle was later towed to the local mechanic…
The contact owns a 2002 Ford Windstar. The contact stated that while driving approximately 30 MPH, there was an abnormally loud sound coming from the rear of the vehicle. The contact lost control of the vehicle and drove off the side of the roadway. The vehicle was later towed to the local mechanic who discovered that the rear axle had fractured due to severe rust. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The local dealer was not notified. The failure mileage was 125,000.
- Structure · Suspension
The contact owns a 2002 Ford Windstar. The contact received notification of NHTSA Campaign Number: 10V385000 (Suspension) and 11V030000 (Structure) however, the parts to do the recall repairs were not yet available. The local dealer was not contacted. The contact stated that the manufacturer had…
The contact owns a 2002 Ford Windstar. The contact received notification of NHTSA Campaign Number: 10V385000 (Suspension) and 11V030000 (Structure) however, the parts to do the recall repairs were not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact stated that the subframe was severely corroded. The failure mileage 59,839.
- Structure › Body › Door
The driver and passenger side sliding doors tend to not open or close correctly sometimes you have to manually pull them open or they do not completely close and you have to bump the back end of it to close right
- Electrical system · Engine · Vehicle speed control
The gauges are acting crazy which causes the engine to jerk or the transmission and then it starts making the lights flicker in the interior and the gauges start sticking. It seems to make the overflow on the radiator to empty more because it is causing the sensors in the electrical for the parts…
The gauges are acting crazy which causes the engine to jerk or the transmission and then it starts making the lights flicker in the interior and the gauges start sticking. It seems to make the overflow on the radiator to empty more because it is causing the sensors in the electrical for the parts to go crazy and run hot. Sometimes it only does it every so often but after getting the reserve hose on the power steering that connects to the reservoir to the coolant the battery was drained. Then going after getting it charged down the highway it caused the interior lights radio and seat and turn signals not to work when coming to a complete stop and it was idling the dashboard and all the lights were coming back on once given a guess it winded up not working again causing the battery to become hot or warm and acid you can smell in the air like rotten eggs. It is causing the overflow tank of the radiator to evaporate more or come out quicker and it is causing other component parts to react strangely which I'm afraid will cause a fire in the vehicle and the idling is not correct also on it now
- Wheels
The rear axle of my 2002 Ford Windstar completely fractured while traveling on Interstate 75. The rear axle broke while driving about 60 miles per hour on Interstate 75 in Florida. By the grace of GOD my passenger and I survived. In attempting to stop, the van hit the guard rail on the Highway. I…
The rear axle of my 2002 Ford Windstar completely fractured while traveling on Interstate 75. The rear axle broke while driving about 60 miles per hour on Interstate 75 in Florida. By the grace of GOD my passenger and I survived. In attempting to stop, the van hit the guard rail on the Highway. I was able to keep the van in the right lane. The van gave us NO warning. While waiting for the AAA tow truck, a Florida Department of Transportation (FDOT} patrol vehicle stop to ensure we were alright. The FDOT driver inspected the Windstar, took pictures and stated he has never seen a broken rear axle like that before.
- Wheels
My tire starting making a whistle screech sound and a sway and I look under my tire is crooked and my axel beam was cracked. Thankfully my kids were not with me and no one was hurt
- Unknown or other
The contact owns a 2002 Ford Windstar. The contact stated while driving approximately 30 MPH, the vehicle experienced severe vibration when the rear axle fractured causing the driver to almost lose control of the vehicle. The cause of the failure was not determined. The local dealer and…
The contact owns a 2002 Ford Windstar. The contact stated while driving approximately 30 MPH, the vehicle experienced severe vibration when the rear axle fractured causing the driver to almost lose control of the vehicle. The cause of the failure was not determined. The local dealer and manufacturer were notified of the failure. The contact was informed that the VIN was not included in the NHTSA campaign number 12V194000 (Suspension). The contact indicated that the vehicle had experienced the same failure listed in the recall. The failure mileage was 185,000.
- Suspension
Broken rear axle on the van. The axle has broken where the reinforcements were welded in from the recall in 2010. NHTSA action number is PE10016. So, the corrective action did not work and now I have broken axle as a result. The axle broke while driving the van and we were very fortunate to be driving at a slow rate of speed.
- Suspension
The rear axle broke in half without warning while driving down the road. Prior to breaking the axle looked to be in good shape. upon looking it up ford had previously recalled this part for that specific reason. I called ford after this happened and the informed me there was no open recall…
The rear axle broke in half without warning while driving down the road. Prior to breaking the axle looked to be in good shape. upon looking it up ford had previously recalled this part for that specific reason. I called ford after this happened and the informed me there was no open recall currently. When I called the parts department to order a replacment axle I was informed by the parts counter that they have seen several of these failing in the same way recently. this IS a pacitularly dangerous issuse beacus it looks fine from the outside untill it gives up and the van IS not rusty in general anyway
- Suspension · Unknown or other
Rear axle cracked through on the driver's side, even after a recall patch/repair was made. no collisions, no hard driving. not a corrosion issue. metal IS cracked perpendicular to the axle..across the grain. axle was heard to make noise while backing out of driveway, then vehicle felt…
Rear axle cracked through on the driver's side, even after a recall patch/repair was made. no collisions, no hard driving. not a corrosion issue. metal IS cracked perpendicular to the axle..across the grain. axle was heard to make noise while backing out of driveway, then vehicle felt fish-tailing while drive down paved neighborhood street. turning to the right made noticeable grinding noises from the rear driver's side wheel well. on closer inspection, the rear wheels were severely tilted in at the top, and the axle was clearly, obviously very cracked open on the driver's side, and appears ready to break into 2 halves. the vehicle was recalled in 2010 for axle defects, but the repairs made seem inadequate. the vehicle was dealership maintained.
- Service brakes
ABS and brake light comes on intermittently. I do not have ABS function while the lights are on and it seems to happen more often in warmer weather. When vehicle IS turned off it resets and doesn't come back on until driven a few miles again. According to several forums, this seems to be happening on a large amount of ford windstar's similar to mine or assembled in canada.
- Suspension
I took my van for inspection and was told I cannot get it inspected because the rear axel corroded and has huge hole on it. I was told it was a danger to continue to drive the van like. I've called ford and was told there IS no longer a recall for my van but yet there was a recall back in early 2010 to 2015 and it's exactly was IS wrong with my van. I am scared to get in the highway or drive it for that matter.
- Suspension
TL* the contact owns a 2002 ford windstar. The contact stated while driving 75 mph, the rear axle seized without warning, causing the contact to almost lose control of the steering wheel. The contact managed to regain control of the steering veering the vehicle to the shoulder of the roadway. The…
TL* the contact owns a 2002 ford windstar. The contact stated while driving 75 mph, the rear axle seized without warning, causing the contact to almost lose control of the steering wheel. The contact managed to regain control of the steering veering the vehicle to the shoulder of the roadway. The contact placed the vehicle in park got out and looked under the vehicle and noticed the vehicle rear axle was fractured. The manufacturer was made aware of the failure and informed the contact to take the vehicle to the dealer for a diagnostic test. The vehicle was towed to thoroughbred ford of platte city (1901 e. Prairie view rd, platte city, mo 64079) where the technician inspected the vehicle and noticed the rear axle was fractured. The rear axle was temporarily fixed. The contact attempted to drive the vehicle home however, the rear axle fractured completely while leaving the dealer. No further assistance was provided. The contact referenced nhtsa campaign number: 10v385000 (suspension), 12v195000 (suspension) and 12v194000 (suspension) as possible solutions to the failure however, the vin was not included. The failure mileage was approximately 161,000.
- Suspension
TL* the contact owns a 2002 ford windstar. The contact stated that after replacing the driver's and passenger's side rear tires, the tires started to wear to the inner cord. The vehicle was previously taken to an independent mechanic to be aligned however, the contact was informed that the rear…
TL* the contact owns a 2002 ford windstar. The contact stated that after replacing the driver's and passenger's side rear tires, the tires started to wear to the inner cord. The vehicle was previously taken to an independent mechanic to be aligned however, the contact was informed that the rear suspension was fractured. The contact called thoroughbred ford of platte city, inc. (1901 prairie view rd, platte city, mo 64079) and was informed that there were no recalls on the vehicle. The contact had the vehicle repaired by the independent mechanic. The contact called the manufacturer and was informed that the vehicle was included in and repaired under nhtsa campaign number: 15v608000 (suspension) in 2015 prior to vehicle ownership. The dealer was called back and confirmed the information provided by the manufacturer. The vehicle had been repaired. The failure mileage was 161,000.
- Structure › Body · Suspension
On saturday august 29, 2020 I was driving in my 2002 ford windstar down a road that was under construction. The speed limit of the road IS 35 mph and there IS a current bump in the road at an asphalt elevation change. As soon as I went over the bump it was obvious that something was severely wrong…
On saturday august 29, 2020 I was driving in my 2002 ford windstar down a road that was under construction. The speed limit of the road IS 35 mph and there IS a current bump in the road at an asphalt elevation change. As soon as I went over the bump it was obvious that something was severely wrong with the vehicle. There was a loud "bang" and the vehicle began vibrating wildly and making severe noises. It was obvious that something significant had occurred in the rear of the vehicle. Fortunately I was able to maintain control of the vehicle and pull onto a side street shortly thereafter. I exited the vehicle and immediately noticed the rear driver-side wheel was angled into the body of the van. Upon further investigation, peering under the vehicle it was obvious that the actual cause was that the vehicle's rear axle had fractured nearly completely through (see pictures). In this condition both rear tires collapsed into the vehicle frame. Upon further investigation I discovered that there had already been recalls related to the rear axle on this vehicle. The vehicle was towed to a local ford dealership for inspection. After the inspection, I was informed that the previous recall for the vehicle to install brackets on the axle had been performed in dec 2010 and that they had been installed correctly. Due to this, ford's position was that the recall was done according to specifications related to the recalls and refused to accept responsibility for this safety failure on their vehicle. I tried to contend that the intent of the recall was to prevent the axle from fracturing, which obviously their previous recall "fix" didn't appropriately accomplish. It was a frightening experience to have an axle fracture while driving my vehicle, and ford's previous recall "fix" failed to correct the problem making the vehicle a hazard to drive.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Front Subframe Corrosion Failures
In a January 26, 2011 Defect Information Report, Ford Motor Company (Ford) notified the National Highway Traffic Safety Administration (NHTSA) that it will conduct a safety recall to address corrosion related fractures in the front lower control arm rear attaching brackets and body mount attachments at the rear of the…
In a January 26, 2011 Defect Information Report, Ford Motor Company (Ford) notified the National Highway Traffic Safety Administration (NHTSA) that it will conduct a safety recall to address corrosion related fractures in the front lower control arm rear attaching brackets and body mount attachments at the rear of the front subframe in approximately 425,288 model year (MY) 1999 through 2003 Ford Windstar vehicles manufactured from April 1998 to July 2003 and either sold or currently registered in the following high corrosion (Salt-Belt) states:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Utah, Vermont, West Virginia and Wisconsin (NHTSA Recall No. 11V-030, Ford Recall No. 11S16).According to Ford, separation of a front lower control arm rear attaching bracket may result in a lower control arm separation and separations of both front subframe rear body mounts may result in separation of the steering intermediate shaft.Either condition could result in diminished vehicle directional control, increasing the risk of a crash.Dealers will inspect the lower control arm rear attachment flanges and the rear body mount sections of the subframe on the right (passenger) and left (driver) sides of the vehicle.Owners of vehicles that pass the inspection will be notified when to return for installation of reinforcement brackets to extend the durability of the front subframe assembly in affected areas in the presence of corrosion.Owners of vehicles that do not pass inspection, but can be repaired, will be offered transportation until parts become available.Repurchase offers will be extended to owners of vehicles that cannot be repaired with the reinforcement brackets.This investigation is closed.
- Front Subframe Corrosion Failures
The Office of Defects Investigation (ODI) has identified 346 complaints to ODI and Ford alleging fracture, cracking and or excessive corrosion of the front subframes in model year (MY) 1999 through 2003 Ford Windstar vehicles.Approximately 97 percent of these complaints (334) involve vehicles that have been operated…
The Office of Defects Investigation (ODI) has identified 346 complaints to ODI and Ford alleging fracture, cracking and or excessive corrosion of the front subframes in model year (MY) 1999 through 2003 Ford Windstar vehicles.Approximately 97 percent of these complaints (334) involve vehicles that have been operated in Salt Belt states, which make up approximately 60 percent of the subject vehicle sales in the United States.The front subframe, sometimes referred to as the engine cradle, is a structural component of the Windstar vehicles that carries the engine, transaxle, steering rack and certain front suspension components (e.g., lower control arm).For complaints with sufficient information to identify the location of the failure, most describe problems with the rear mounting bracket for the front passenger-side lower control arm with some related to the rear body mount attachment located in the same general area of the subframe (right-rear section near the front passenger wheel).The remainder of the reports allege fracture of the front subframe at other or, most often, unspecified locations.Almost all of the complaints that specified the side of the vehicle indicated that the problem occurred on the right/passenger side (106), with only a few indicating the left/driver side (2) or both sides (3) were affected.Ford and several complainants attributed the right-side failures to the routing of the air-conditioning lines above the front subframe on that side of the vehicle, further noting that condensation has been observed dripping onto the front subframe in the area of the affected components (the A/C drain tube is also located on the right side, near the front subframe).ODI has identified 93 complaints related to lower control arm attachments, including 80 that appear to involve complete separations.All but one of these involved vehicles from Salt Belt states.All three crash incidents appear to be related to lower control arm separations, including one road departure into a road-side sign resulting in a totalled vehicle and a lane departure into another vehicle.Almost half of the ODI complaints related to control arm separation occurred at speeds greater than 20 mph and about a quarter occurred at highway speeds.Three-quarters of these complaints allege experiencing difficulty controlling the vehicle and about 40 percent appear to have resulted in departures from the intended lane of travel.Testing by both Ford and NHTSA have demonstrated that lower control arm separation from the rear attachment bracket results in significant toe out of the affected wheel, which affects the driver's ability to control vehicle direction.According to Ford, moderate braking improved vehicle controllability by reducing the amount of toe out, possibly explaining incidents that did not allege a loss of control.ODI's analysis of complaints related to the rear body mount identified 41 complaints (ODI only).These complaints generally report experiencing progressively worsening noise concerns when turning, accelerating or braking.Although, some of the complaints that appeared to involve a complete separation of the body mount alleged difficulty steering, the effects on vehicle control from this failure mode do not appear to be as great as those resulting from control arm separation.However, ODI is seeking more information regarding two complaints which alleged that body mount failure resulted in disconnection of the steering wheel from the steering rack (one occurred during vehicle service).This investigation has been upgraded to an Engineering Analysis (EA10-007) for subject vehicles sold or currently re
- Rear Axle Cracking
In a letter dated August 26, 2010, Ford Motor Company (Ford) submitted a Defect Information Report notifying NHTSA that it will conduct a safety recall (NHTSA Recall No. 10V-385) to address a rear axle defect in model year (MY) 1998 through 2003 Ford Windstar vehicles built at the Oakville assembly plant from…
In a letter dated August 26, 2010, Ford Motor Company (Ford) submitted a Defect Information Report notifying NHTSA that it will conduct a safety recall (NHTSA Recall No. 10V-385) to address a rear axle defect in model year (MY) 1998 through 2003 Ford Windstar vehicles built at the Oakville assembly plant from September 1, 1997 through February 28, 2003 and either sold or currently registered in high corrosion (Salt-Belt) states where the use of salt and other corrosive chemicals may be used to treat snow/ice covered roads.The following states are included in Ford's recall:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. The subject vehicles utilize a Stamped/Formed axle assembly manufactured by Benteler automotive Corporation of Galesburg, MI.According to Ford, after many years of vehicle service in the Salt-Belt states, corrosion can weaken the rear axle, making it susceptible to torsional stress.There is a risk that the combined effects of corrosion and stress can lead to cracks which, if undetected, can propagate and result in a complete fracture of the axle.A completely fractured axle can affect vehicle handling and increase the risk of a crash.To correct the safety defect, Ford will initially inspect all of the subject vehicles brought into Ford/Lincoln-Mercury dealerships for possible cracked axles.Owners of vehicles without cracked axles will be notified when to return for the installation of reinforcement brackets to extend the axle durability in the presence of corrosion.Owners who have vehicles with cracked axles will either be offered a repair or alternative transportation until parts become available. On May 13, 2010, the Office of Defects Investigation (ODI) opened PE10-016 to investigate complaints of rear axle cracking in MY 1999 through 2003 Ford Windstar minivans.Combining ODI and Ford complaint data, ODI is aware of a total 891 complaints alleging rear axle cracking in the subject vehicles.Over a third of the complaints (334) allege that the cracking progressed to a complete fracture of the rear axle, including 8 allegations of crashes resulting in 3 injuries. Approximately 57 percent of the subject vehicles (524,661) were sold in Salt-Belt states covered by Ford's recall and Ford estimates that approximately 463,000 of these remain in service.Ninety-six percent of the complaints (858) and all of the complaints alleging complete fracture were from the recall region.The action taken by Ford is sufficient to resolve the issues raised by this investigation.Accordingly, this investigation is closed.
- Engine compartment fires
Ea08-021 IS closed with ford's actions in recall 09v-399 recalling approximately 4.5 million vehicles equipped with texas instruments speed control deactivation switches (scds).with this recall ford has now recalled all of the approximate 16 million ford model vehicles that were manufactured from my 1992 through 2003…
Ea08-021 IS closed with ford's actions in recall 09v-399 recalling approximately 4.5 million vehicles equipped with texas instruments speed control deactivation switches (scds).with this recall ford has now recalled all of the approximate 16 million ford model vehicles that were manufactured from my 1992 through 2003 with a texas instruments scds.nhtsa will continue to monitor the recalled vehicles to ensure remedies installed by ford tomitigate the potential for scds related fires are effective.the agency reserves the right to take further action if warranted by the circumstances.see attached closing report for further details.
- Engine compartment fires
Odi has received 134 consumer complaints, 285 manufacturer complaints, and 137 manufacturer warranty claims alleging incidents of engine compartment fire in model year (my) 1995 thru 2003 ford windstar vehicles.two of the odi complaints allege the fires caused structural damage to the complainant's home.of the 134 odi…
Odi has received 134 consumer complaints, 285 manufacturer complaints, and 137 manufacturer warranty claims alleging incidents of engine compartment fire in model year (my) 1995 thru 2003 ford windstar vehicles.two of the odi complaints allege the fires caused structural damage to the complainant's home.of the 134 odi complaints, 36 allege the fire occurred while the vehicle was parked, 72 allege the fire occurred while the vehicle was running and 26 of the complaints do not specify if the vehicle was running or not.further review of the odi complaints shows that 72 allege that the speed control deactivation switch (scds) caused the fire and 10 allege that the scds leaked brake fluid on to the ABS module resulting in the fire.there were 52 that did not identify a cause or that identified miscellaneous other causes.odi has also received 89 complaints ( not counted in this resume) alleging that the scds developed a brake fluid leak.thirteen of these complaints say that the leak at the scds resulted in braked fluid reaching the ABS module.this pe has been upgraded to an engineering analysis (ea) to further evaluate the cause of the fires and assess the scope, frequency, and safety consequences of the alleged defect.
- Power sliding door opening
The subject vehicles are equipped with single or dual power sliding doors (psd).approximately 111,000 vehicles have dual power sliding doors.the psd IS opened by any of 5 methods, the inside or outside manual door handle, the key fob, the overhead console switch and the b-pillar switch.the door may be opened only…
The subject vehicles are equipped with single or dual power sliding doors (psd).approximately 111,000 vehicles have dual power sliding doors.the psd IS opened by any of 5 methods, the inside or outside manual door handle, the key fob, the overhead console switch and the b-pillar switch.the door may be opened only under these conditions: ignition key IS in off/accessories/on/start position, gear selector in park, vehicle speed less than 6 mph, and door unlocked.the psd latch IS located at the rear of the door and has a secondary and primary latch position.full and proper closure engages both the secondary and primary latch.with the ignition in the on position, as the gear selector IS moved out of park the door automatically locks and that action mechanically isolates the latch, secondary and primary, from all latch release connections.in addition to the reports alleging door opening while driving, ford has received approximately 5,700 reports that allege the door does not close properly or pops open with no mention of while driving.ford's investigation into these report included owner interviews, vehicle by-backs and testing of consumer vehicles.it found that allegations of door opening while driving were in fact reports of doors not being properly closed initially and subsequently opening to the secondary latch position as a result of vehicle vibrations or driving maneuvers.ford's testing of consumer vehicles did not result in any recurrence of psd opening while being driven.odi interviews with owners affirmed the allegations of psd opening while driving; however owners indicated the event IS not a regular occurrence (i.e.,it occurred only once or has not occurred recently) and that the unintended psd opening may not be able to be duplicated.in contrast, the improper closing of the psd (latching on the secondary but not the primary latch) can be duplicated, and odi verified this during an inspection of a consumer vehicle.in this condition (secondary but no primary latch), when the vehicle's gear selector IS moved out of park position, a warning chime sounds and warning message appears on the instrument panel.most reports and warranty claims were filed in the early service-life of the vehicle and peaked around the 18-month in-service time period.odi and mfr complaint trends are declining over the last 8 quarters.there IS no alleged injury associated with occupant falling out while the vehicle IS in motion.no failure mode causing full door opening while vehicle IS in motion has been verified (reproduced by odi or by trained service technicians at dealerships) during this investigation.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10205035Safety recall 10S13 - Rear axle corrosion - requests for recall service action
- 10205030Safety recall 11s16 - LCA rear attaching flanges or rear subframe body mount corrosion - requests for recall service action
- 10183771For 1998-2003 Windstar vehicles Safety Recall 10S13 has been issued for vehicles that are operated in high corrosion areas for an extended period, where the rear axle could potentially fracture. If the rear axle should completely fracture, vehicle handling may be affected which could increase the risk of a crash.
- 10183766For 1999-2003 Windstar vehicles Safety Recall 11S16 has been issued for vehicles that are operated in high corrosion areas for an extended period, where a front subframe lower control arm (LCA) rear attaching flange or rear body mount could separate from the vehicle subframe. Separation of one LCA attachment or both rear body mounts may result in a loss of vehicle directional control, increasing the risk of a crash.
- 10074725Summary to be provided on a future date.
- 10058105Ford: safety recall on front subframe lower control arm (lca) rear attaching flange or rear body mount that can separate from subframe if vehicle IS operated, for extended period, in high corrosion areas. Model 1999-03 windstar.
- 10058104Ford: safety recall concerning rear axle fracturing if vehicle IS operated in high corrosion areas for and extended period. Model 1998-03 windstar.
- 10056623Ford: on some minivans, rear axle will fracture, in high corrosion area, after operating for an extended time period, and vehicle handling ability will be affected. Model 1998-2003 windstar.
- 10056612Ford: a safety recall has been issued on minivans where lower control arm (lca) of front subframe attaching rear flange or rear body mount can separate due to corrosion. Model 1999-2003 windstar.
- 10016808Erratic fluid level reading on transaxle dipstick-leaks-4f50n, AX4N, AX4S transaxle.
- 10014138Safety belt retraction speed.
- 10014086General (pcm) power train control module programming procedures.
- 10014062Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10013069Compass displays incorrect direction reading.
- 10013062Roof ditch material cracking. This includes 1997-2003 F-150 and 2002 blackwood models. Service tip.
- 10013060Climate control a/c service tech tips.
- 10012954Safety belt web stop button service.
- 10011159Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10010714Spark knock on acceleration - vehicles equipped with 3.8L engine only.
- 10009321Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns.
- 10009320Diagnostic trouble code b1342 (restraints control module (rcm) fault. Update.
- 10008580Lamp-brake-invadvertent disabling of brake shift interlock.
- 10008579Restraint system-air bag deployment strategy with advanced restraint system.
- 10008350Servicing body side molding or cladding / contact request.
- 10008321Squeak noise from the front spring area.
- 10008320Clunk/squeak from the front stabilizer bar area (qsf).
- 10008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application.
- 10008273Trailer tow service kit - service tip.
- 10008252Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. Additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
- 10008240Power steering noise.
- 10008201Warning indicators-parking aid-reverse sensing system (rss) and forward sensing system (fss)-false activation of warning tone-service tips. Update.
- 10008198Replacement of lower seat-to-floor latches on vehicles equipped with 2ND and 3RD row seats. Demonstration / delivery hold. Compliance recall 03c05.
- 10008183Groan/buzz/vibration when the gear selector IS in park with the vehicle parked on an incline. This bulletin updates previous bulletin 17358, dated 11/01/2003 to include 2005 models.
- 10008151Crease in the headliner above the left a-pillar.
- 10007386Trailer tow electric brake switch/module connector may be difficult to locate in the vehicle and for certain 1999-2001 vehicles, the location IS not clearly identified in the wiring diagram manual.
- 10007365Power sliding door operation and diagnostic service tips.
- 10007360Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. Additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
- 10007354Windshield cowl panel grille (leaf screen) breaking at the grille opening.
- 10007207Customer satisfaction program 02m01 supplement #4. Certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. Supplement #3. Supplement #6.
Every Ford Windstar model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.