NHTSA Complaint #10207702 — 2000 FORD WINDSTAR

CATASTROPHIC FAILURE OF THE RIGHT LOWER CONTROL ARM MOUNTS AT THE SUBFRAME OCCURRED WITH NO WARNING OR PRIOR SYMPTOMS. THE VEHICLE IS A 2000 FORD WINDSTAR WITH APPROXIMATELY 95K MILES. AT THE TIME OF THE FAILURE THE DRIVER WAS PULLING AWAY FROM A CURB WHEN THE CONTROL ARM MOUNTS BROKE CAUSING THE WHEEL TO SWING AWAY FROM THE VEHICLE AND THE DRIVE AXLE TO PULL OUT OF THE TRANSMISSION. THE VEHICLE WAS TOWED TO A LOCAL SERVICE STATION WHERE IT WAS EXAMINED. THE DEALER WAS CONTACTED WHO IN TURN INSTRUCTED ME TO CONTACT FORD MOTOR COMPANY DIRECTLY. UNDER THE DIRECTION OF FORD MOTOR COMPANY THE VEHICLE WAS TOWED TO THE DEALER TO DETERMINE THE CAUSE OF FAILURE. THE DEALER DETERMINED THAT THE SUB-FRAME WAS RUSTED OUT IN THE AREA AROUND THE PASSENGER SIDE CONTROL ARM MOUNTS. FORD HAS REFUSED TO OFFER ANY ASSISTANCE IN FIXING THE PROBLEM. A SEARCH OF THE NHTSA COMPLAINT DATABASE REVEALED 12 OTHER COMPLAINTS OF SIMILAR FAILURES WITH 1998-2001 WINDSTARS. (ODI #S: 10152076, 10103097, 10152712, 10138539, 10183135, 10171784, 10173473, 10153590, 10200106, 10005872, 761511, 10172459) THERE APPEARS TO BE A TREND RELATED TO EXCESSIVE CORROSION LEADING TO PREMATURE FAILURE OF THE REAR PORTION OF THE SUBFRAME ON THE PASSENGER SIDE. ONE POSSIBLE FACTOR COULD BE THE PLACEMENT OF THE AIR CONDITIONER SYSTEM AND THE TENDENCY FOR CONDENSATION TO DRIP ON THIS PORTION OF THE FRAME WHENEVER THE SYSTEM IS IN COOLING OR DEFROST MODE CAUSING ACCELERATED CORROSION. THIS IS A SEVERE FAILURE THAT IS PREMATURE, NOT EASILY DETECTABLE, POTENTIALLY FATAL, AND WILL LIKELY OCCUR MORE FREQUENTLY AS THESE VEHICLES AGE. I STRONGLY URGE THE NHTSA TO CONDUCT AN ENGINEERING INVESTIGATION REGARDING THIS FAILURE. *TR