Ford Windstar Recall: 575K Minivans May Suffer Rear Axle Fracture
About 575,000 older Ford Windstar vans are being recalled in cold-weather states and Canada due to the risk that the rear axle may fracture from corrosion.
Ford Motor Company announced the Windstar recall in a press release Thursday. The recall will affect minivans from model year 1998 through 2003 in 21 states that make heavy use of road salt during the winter months.
The Ford Windstar minivan recall follows an investigation by the National Highway Traffic Safety Administration (NHTSA) that was initiated on May 13, after federal investigators received an increasing number of reports about the axles fracturing, including reports of at least two auto accidents. There have been nearly 1,000 reports to the NHTSA in total regarding the problem with Ford Windstar vans.
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According to the NHTSA, the design of the axle allows road salt slush to collect and linger on the axle, promoting rust and eventually raising the risk of the axle fracturing. A fractured axle could lead to a loss of control of the vehicle and increases the risk of an accident that could cause property damage, severe injury or death.
The minivan recall affects 463,000 vehicles in the U.S. states of Connecticut, Delaware, 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, as well as the District of Columbia. The remaining 112,000 vehicles are located in Canada.
Ford has announced that it will notify affected owners in the very near future and request that they bring their vehicles to local Ford dealers for inspections and repairs, if necessary. Dealers will either reinforce the axle or replace it, and will provide a rental for customers whose vehicles are being repaired. The Ford Windstar itself is no longer in production.
Photo Courtesy of IFCAR via Wikipedia Commons Public Domain
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230 Comments
To Chris: You are an idiot also. My husband was a Ford dealer. We cleaned the underside of our van, garaged it, took it for inspection before trips, maintained it very well. This was a Ford Defect. My family was almost killed when the axle went out on the interstate. FORD was negligent. To you ignorant people writing on this site, like Chris and Ryan, get a life. You just want to cause trouble. YOu have no clue what its like to live through a devistating situation like this. Get a life!
Picked up my 2001 Windstar on 3/25 after 5 months (11/1/10 it was towed to the dealer) of sitting on the dealer’s lot. In the beginning, dealer said they start the vehicles every day. I know that’s an outright lie because after several snowstorms that we’ve had, I went by the dealers lot and no snow had been touched, removed or stepped in around the car. Ford said they are also supposed to ‘drive’ the cars a bit once each month to avoid flat spots on the tires. However, mine was undrivable because the axle had already broken (twice – first left side then right); so that didn’t happen either and I have flat spots on the tire(s). On Friday, April 1, one week after picking the car up, it wouldn’t start. Had to have it towed to my own mechanic who said the starter had corroded and melted. So he fixed it ($400) thinking it was just that. Three days later, car died again. Yesterday, I found out that there is an antifreeze leak inside the engine which means a “cracked head” or head gasket. My mechanic also said that the started was so severely melted that the only way it could have melted that badly was by someone repeatedly attempting to start the car or that the car severely overheated (and I know it wasn’t me). This problem if we choose to get it fixed will be about $1,600. Clearly, the techs at the dealer could not get the car to start and just kept trying until it finally did (however, never said a word to me about that problem when I picked the car up). I’m about to head into battle with Ford to have this resolved . I have proof that my car was in perfect running condition before they got it. I know that they are going to deny any issues whatsoever, but I’m not going anywhere until they take care of it or have to call the police to have me taken from the dealer bodily. By the way, I was on my way to get gas in the car when the axle broke but never made it, so it was low when the dealer got it. When I picked it up, I prayed that I would make it to a gas station because the tank was virtually empty — more evidence that the car was not started/run in 5 months. Also, the dealer noted on my receipt that the car had to be brought into the shop via forklift. But I’m sure that didn’t cause any damage!!!!!
getting my 2000 windstar back aftter 3 months of down time; ford put me in a sweet ride of a jeep liberty rental. would buy that jeep over the ford anyday. the windstar comes home today, ford replaced the rear axle and replaced the battery. they said they sent many to the scrap yard , but i wonder why mie was able to be repaired . i was hoping for a buy out and sweet trade in offer sicne it is over 10 years old
Got my 2002 Ford Windstar back this week after 5 weeks of driving a rental. I thought wow, I was a lucky one. Well, to my surprise. My van died on me once in the parking lot and again that evening when I got it home. Also my check engine light came on. Called the dealer the very next day and they asked if I could bring it back in. Took it in the that night, got a call the next day….$800 in repairs for a cam sensor and a fuel pump hose. Dealer told me that they contacted Ford and Ford said it wasn’t covered under the warranty for the recall because one those parts aren’t covered and two I drove it off the lot! OH MY. Will be calling Ford Motor Company in the morning! I took a perfectly working car to them 5 weeks ago! Hello, this was from it sitting for that long! FORD NEEDS TO DO SOMETHING ABOUT THESE ISSUES NOW! I like many others on here held Ford to high respect. That is not going to happen anymore. I have told everyone about my problems and WILL NEVER BUY FORD AGAIN! My 70 year old father has been a loyal Ford Customer for over 40 years, guess what…not any more. He’s will never buy another FORD after this incident. Dont’ get my wrong, I commend Ford for the recall but stand behind the issues too. You had to know they were going to happen.
Got the call from dealer yesterday car finally fixed 6 months later! Car ran perfect no problems till axle broke on us November 17th 2010. Car towed and sat in lot till yesterday when I wnet to pick it up with my family. Started up but started missing, I attributed this to standing, started driving in lot to exit and it sounded like the rear was going to fall out, started running rougher as well. Pulled back around building spoke to GM and told him I am not taking this, left with rental. Went back this morning, April 12, 2011, had service manager get in and explained what was wrong, brakes, roughness and noise in front and rear so he decided to drive it. we went about 30ft when he said sorry. I left and called him a few hours later, they left the shocks loose! Called ford to complain about breaks, rough running they said dealer put new plugs in it but it now needed head gaskets!! I called ford a few times to express my concern about the vehicle sitting and was told lets wait till we pick it up, well I am not paying for something that isn’t my fault. My vehicle ran perfectly before the axle broke. The ford rep said they would not help me s they weren’t sure of the condition before the car was there, I told verbatim “ listen why would I put my family in a car that I dangerous” he could not answer but his other response was “Our engineers say that there shouldn’t be a problem with the vehicles sitting this long” my response to him was “ is this the same engineer that designed the axle cause if it is I don’t have any faith in their design” no response to that as well. So now I am stuck with a car I cannot sell, nor trade in! my KBB value is zilch and ford will do nothing to assist.
I was hearing that same clunking noise before received my recall notice back in October. Ford had my van form 10/16/10 thru 3/23/11 because they had find the part I have 2 call on Monday morning because Im hearing that same notice again. Personally I’m starting to believe they tried 2 rebuild it since reading someone said he could not locate the axle.
Got the call april 4th my 2001 windstar was done. The dealer also told me that he could not keep it running. He thought the head gasket had blown he wanted 1500 to fix the head gasket. I had told the service dept to fix it but I was not happy. They then called to tell me the block was craked instead now they want 2750 to put in a junkyard motor with no warranty. I am totally fed up. They also parked my van outside with no attention given. If my van would have been at home in the garage and ran everyday like normal I don’t believe this would have happened
I have two Windstars,a99 and an 03 .The 03 has a six inch crack in the rear axle which i am now driving a 2011 Chrysler Town & Country rental. Ford has treated me good and Enterprise rental has been great. One other comment i’d like to make is about people talking about blown head gaskets. I do my own engine work and i noticed that my intake gaskets are thick plastic with rubber o-rings .These o-rings can leak after a period of time (maybe while sitting),and can leak coolant down into the oil pan which can look like a faulty head gasket. On my 99 even with new gaskets after sitting for a long period i loosened the oil plug and drained out a small amount of coolant.(water is heavier than oil and goes to the bottom,which that’s the first thing that your oil pump will pick up which will result in abad engine. Thank Bill
Is there any word on whether or not the buyout option will extend to cover the 2002?
I am about to take my van in this Friday to be inspected, and honestly after reading the horror stories I am ready to take the buyout. I’d still buy Ford I think, but man they sure make it hard to want to purchase from them.
I just bought my 1998 windstar about 6 months ago and i learned about the rear axle recall at the end of feb i took my van for inspection on 3/1/11 and was also put into a loaner that same day. i picked up my van today 5/13/11 to find that my passenger window door lock and speaker no longer works my air conditioner does not work, i need a new battery and alternator, and muffler. i have a nice size dent in the front passenger fender and pick paint on my passenger mirror. it also looks as if the the right headlight cover has been replaced. I also have a huge crack down the right side of my windshield. i also have 5 check engine code so i can not even pass an echeck. i will never go back to ford again! and will make sure that everyone knows how they do not take care of customers!
Just got my van back May 20th, Ford had it since Nov. 1, 2010. The dealership told me that all the tires were dry rotted, the battery was replaced, and the van was ready to be picked up. They said one of the tires had a leak. I figured it was something I needed to just watch. It was flat by the time I drove 6 miles home. Ford Co. wouldn’t do anything and asked if the dealership was aware I was driving it from the lot. What kind of question is that. At first the dealership told me oh well and it wasn’t their problem. Then I spoke to management at the dealership and the man was wonderful and sent someone out immediately to replace the one bad tire, though I was already told that I cannot replace just one tire. Yesterday the alternator went out, not sure if that could be related to it sitting for almost 7 months. But the van runs worse than when it went in, dies out when idleing. Who knows. Loved the free rental but now have a car that is not reliable.
We have 3 vans. Two are Fords. The front coil spring in the one broke two weeks ago. It is still sitting in driveway. Today, our 16 yr old daughter was driving, the other van, across town, not more than 3 miles from home, one of the coil springs in the front broke on it. Just going down a 25 mph road. This sounds to me like the coil springs on these vans were not any good. These are .
I have had so many issues with this 99 ford windstar its unreal . who do i contact to resolve this ??
I have a 2001 Ford Windstar. While taking off at a green light, the carriage dropped and my accelerator went to the floor and I had no steering. This was on a highway to make things worse. Thank goodness it was a Saturday morning, without much traffic because I went straight into the other lane. Could have been dire. The power steering pulley and serpentine belt broke which Ford did not cover. They did replace the motor carriage and rear axle for no charge, but wouldn’t cover anything that broke when the carriage broke. I don’t get it.
WOW WOW WOW! AMAZING STORIES GUYS AND GOD BLESS YOU ALL. I GUESS I WILL TAKE IT THIS WEEK TO GET INSPECTED AGAIN. THANK YOU ALL1
how do i get i n the ssuit i had my kids in it when it broke
I live in north Carolina and the rear axle broke on my windstar 2000 I was looking for a replacement over the web to fix it when I found out that ford recall those minivan I call the ford dealership end they said not notice of that. The only way to replace is if I have an insurance with ford. Why only in certain states? What I can do? Any body can give me hand up?
Have 2003 windstar limited, rear axle broke on Saturday, called ford on Monday morning, gave ford info and vin # they come back and tell me that my vehicle is not part of the recall because my vehicle had a different axle and was out of warranty. Every vehicle in this recall is out of warranty. Total BS axle broke in same spot as all the ones I have seen online and on you-tube. Very very upset with FMC.
In March of 2008 our Ford Windstar was making noises. When my husband looked underneath the van, it almost made him sick. The rear axle had a huge crack through it. We had just been traveling 70 miles an hour on the interstate the day before. Of course, when he took it to the dealership they said “we have never seen anything like this before.” We still owed money on this vehicle and ended up having to trade and loosing money on that. Since then we have been driving Mitsubishi vehicles and will never drive a piece of crap Ford vehicle again. EVER! We also had problems with a Ford Windstar before where the head gasket went bad. The recall for that came after the problems and the recall only covered the head gasket and not the whole computer board that blew because of the bad head gasket. Should have learned our lesson then, but we didn’t. The thing that really makes me sick with Ford is that if they would have started checking into these issues early in 2008 when we started reporting a problem, some lives could have been saved!
I have a 2001 Winstar which was in for the recall on the rear axle, there were clamps put on. Do not feel safe with this fix, my rear axle broke right under the clamp and I called Ford they told me the warranty on the fix is 3 month or 5000 Kilometers. A joke, when you are dealing with peoples lives. Expect no help from FORD. I will never drive another.
i have ford windstar in Europe,also broken rear axle,ford usa said-no recalls for this axle for my car.Ford USA dont know who is real seller in EU .First central office send me to Finland ford,this seller-no we do not sell this cars…Then send me to another finland company(for USA said yes contact with this company) .This company said-no no -we just sell in finland and for finland buyers…So same car same problem and problem with Ford USA Company…i dont want buy any other USA For car in my live…
NOT sure iof my van is affected i live in philly araea. BUT this van served me well with some huge reapirs lately 600$ new water pump and motor mounts NEW baterry $60 alternator last year $85 cost installed
starter 3 yrs old guaranteed for life of vehicle $300 any way was told by pep boys parts guy this is the worst model ever for ford he said more parts are sold for windstars than all other makes. Anyway this is my last ford product and i had them all MERC Grand marquis only 63,000 miles on it dead in junk yard after 4 years. consantly after 2nd year every month had to fix something including broken tie rod while i was driving thank god low speed no one around.
Lincoln continental mark 3 plaese every week that gas pig killed me got crushed in accident was happy to unload it to scrap yard for $300
old ford fairmount was ok but got whacked in cuty streets bought an old olds 98 after that.
Anyway got to replace two sensors reset the vehicle by removing battery terminals so the CHK ENG goes off and cross fingers it stays off replace both tail lights and then sell it for about $1000 knowing next owner gets at laest a year trouble free only thing is seats removed cause i used this van for scrap iron work. SO i have to list as such.
We were driving 60 miles per hour on the Freeway , when our rear axel snapped in two on our Ford Windstar. We had our entire family in our van. We heard a load noise, smoke was everywhere. We were all scared to death. We were able to bring the van to a sudden stop, but our entire family was traumatized. We stood on the side of the road ( at midnight). Waiting on a friend to pick us up. We took our van to a Ford dealer when we received a recall letter. They supposedly fix the van, by putting two little brackets on the rear axel. Now Ford is saying they rant responsible, because the auto place we took our van to put the brackets on wrong!! REALLY? FORD, are you even serious right now? I’m without a car and this is very stressful. Also people have died from your NEGLIGENCE! Please stop putting lives in danger, please put a new rear axel on these vans, not a cheap set of brackets..
Our axle broke even after Ford put cheap brackets on it. Ford refuses to replace the bad axle because they say the recall has since expired. I really wish there was a away to sue Ford to get them to care more. We had the axle welded but that will not last long.
I need to get a new vehicle.
http://www.carcomplaints.com/Ford/Windstar/2003/suspension/rear_axle_control_arm_cracked_at_point_fixed_under_recall.shtml
this is a link to another recall site, i include pictures and an update
AHHHHHHHHHHHH!!!!! About 2 weeks ago the rear axle of our Windstar broke. We took it to the corner shop and they did a VERY temporary fix to literally get it home. The following day I found out about the recall (we’re not the first owners) and I called our local Ford (from whom we purchased an older Fusion from). They informed me that there was actually THREE recalls on it and asked to drop it off. I dropped it off only for them to tell us that they, per Ford, could not fix it because we “attempted” to fix it. We picked up yesterday and it broke AGAIN because of the TEMPORARY fix that was done when we “attempted” to fix it. Called Ford and they said they couldn’t do anything about it. RIDICULOUS how they can get “around” what is an obvious (even to the untrained eye) simple solder and not repair it!!!!!
We’ve owned our 1998 Windstar for just 3 years and have liked it. So disappointing to see this recall and also not see Ford jumping through hoops to pay for a new axle, period. Instead, the letter talks of the brackets possibly “improperly” installed. This hints that if properly installed all is well. Pretty easy to find out that the brackets even if “properly” installed the axles are going to fail. It’s not an “if’ but a “when”. Also, try to find out what they even mean by “improperly” . Can’t they just admit the axle is inferior, dangerous, and must be replaced?
My son’s winstar axle broke while driving. Stranded him and a bridge, Very dangerous. Dealer indicates that time for his recall has expired so the cost of repair is left to him. How can they put a time limit on a recall this dangerous?
I bought a 01 Windstar only to have the rear axle crack in half exactly where all the others have .took it to Ford dealer cause they said bring it in .only to have them tell me it would be 1000$ to fix said no recall for me .then said I can pick up my van as long as I paid the 167$ inspection fee Wich I never agreed to or signed any thing to that affect.never even mentioned there would be a charge to look at it plus all u have to do is look under the back of the van and you will see the cracked in half axle
2002 Ford Windstar rear axle broke, left me stranded almost wrecked, trying to stop the vehicle. They said they was the no recall for my model in the axles contact local dealerships all lied and put me off like I was trying to get something for nothingI hope they go out on strike and starve to death. Ford like everyone else now has outsourced the answering service so you speak to people that don’t even speak English American made my ass.