NHTSA Complaint #10629768 — 1999 FORD WINDSTAR

CHRONIC VIBRATION / SHUTTER NOTICED DURING MODERATE BRAKING. NEW RACK & PINION INSTALLED IN 2009; NEW BRAKE ROTORS AND PADS INSTALLED IN 2012, OFFERING SLIGHT IMPROVEMENT. WIFE HEARD "CRACKING NOISE, EXPERIENCED DIFFICULTY MAKING LEFT TURNS & DROVE ABOUT 45 MILES, PARKED AT HOUSE, FRONT SUBFRAME FRACTURE / SEPARATION PASSENGER SIDE, RESULTING IN STEERING RACK TILT UP APPROX. 3/4" ON RIGHT SIDE AND EXTREME TOE OUT ON RIGHT FRONT TIRE (APPROX 20 DEGREES VS. LEFT). NOTICED WHILE ATTEMPTING TO BACK UP - UNDRIVEABLE CONDITION. COLLATERAL DAMAGE TO STEERING SHAFT BOOT, RACK & PINION SEAL (FATIGUE / LEAKAGE), AND O2 SENSOR CABLE (SEVERED). DISCOVERED MISSING LEFT REAR SUBFRAME MOUNTING BOLT. CAR MANUFACTURED IN CANADA. NOTICEABLE EXPOSURE / DRIPPAGE OF AMBIENT CONDENSATION ON TOP OF SUB-FRAME, BELOW REFRIGERATION LINES / FREON DRYER CANISTER, DURING A/C OPERATION (GULF COAST HIGH HUMIDITY / SALT AIR EXPOSURE COULD BE AN INFLUENCING FACTOR FOR CORROSION). REFERENCE PREVIOUS NHTSA ACTION #PE10-026 (7/20/10); FORD FRONT SUBFRAME ENGINEERING ANALYSIS EA10-007 (SALT BELT STATES); RECALL 11S16. FRACTURE AREA OCCURRED IN CURVED PORTION OF SUBFRAME BRACKET / STEERING RACK MOUNT (FORD PART #3F2Z5C145CA - $2100 MATERIAL + LABOR $715). STREAK OF RUST IS CLEARLY EVIDENT ALONG WHAT APPEARS TO HAVE BEEN A VERTICAL CRACK LEADING TO THE FRACTURE / SEPARATION SITE BENEATH THE STEERING RACK BOOT. PHOTOS AND PARTS DIAGRAM AVAILABLE UPON REQUEST. FORD CUSTOMER SERVICE CASE # CAS5113626 DECLINED. TOLD TO WRITE LETTER. SEEKING MANUFACTURER BUY-BACK RELIEF.