2002 FORD WINDSTAR Structurebody Problems

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

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

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...

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE STOPPED, THE CONTACT HEARD AN UNKNOWN PART DETACH FROM THE VEHICLE. THE CONTACT STATED THAT THE STEERING WHEEL THEN BECAME DIFFICULT TO TURN. THE VEHICLE WAS TOWED TO THE RESIDENCE. AN INDEPENDENT MECHANIC WAS CONTACTED BY PHONE AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 10V385000 (SUSPENSION) AND 11V030000 STRUCTURE). THE VEHICLE WAS TAKEN TO METRO FORD CHICAGO (6455 S. WESTERN AVE, CHICAGO, IL 60636, (773)776-7600, TO HAVE THE RECALL REPAIRS PERFORMED. THE CONTACT WAS INFORMED THAT AN UNKNOWN BUSHING NEEDED TO BE REPLACED PRIOR TO THE RECALL REPAIR BEING PERFORMED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 144,000.

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT NOTICED THAT THERE WAS WATER ENTERING INTO THE VEHICLE FROM THE FRONT WINDSHIELD. IN ADDITION, THE TRIM BY THE FRONT WINDSHIELD AND FRONT FRAME ON THE PASSENGER SIDE WERE RUSTING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER AND DEALER WERE NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 125,000. THE VIN WAS NOT PROVIDED.

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. WHILE DRIVING 40 MPH, THE REAR OF THE VEHICLE BEGAN VEERING TO THE RIGHT AND LEFT. THE CONTACT TEMPORARILY LOST CONTROL OF THE VEHICLE, BUT MANAGED TO PULL OVER TO THE SIDE OF THE ROAD. THE CONTACT DROVE TO AN INDEPENDENT MECHANIC WHO QUICKLY DIAGNOSED THAT THE REAR AXLE WAS RUSTED AND FRACTURED IN HALF. THE CONTACT TOOK THE VEHICLE TO DORIAN FORD (35900 GRATIOT AVE, CLINTON TWP, MI 48035, (586) 792-4100) IN 2016 FOR AN UNKNOWN RECALL REPAIR REGARDING THE BRACKETS FOR THE REAR AXLE. THE DEALER CONFIRMED THAT THEY INSPECTED THE VEHICLE AND PASSED IT ON FEBRUARY 9, 2016. THE DEALER REFERRED THE CONTACT TO THE MANUFACTURER, BUT THEY WERE ONLY CONCERNED THAT THE VEHICLE WAS NO LONGER COVERED BY A WARRANTY AND DID NOT ASSIST. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 113,643. *BF CONSUMER STATED DORIAN...

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. WHILE DRIVING AT AN UNKNOWN SPEED, THE REAR AXLE FRACTURED WITHOUT WARNING. THE VEHICLE WAS UNABLE TO BE DRIVEN AND WAS TOWED TO BEAU TOWNSEND FORD LINCOLN (1020 W NATIONAL RD, VANDALIA, OH 45377, (937) 898-5841). THE DEALER DIAGNOSED THAT THE BRACKETS FAILED TO SECURE THE REAR AXLE, WHICH THEN CAUSED THE REAR AXLE TO PREMATURELY FRACTURE. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V608000 (SUSPENSION). THE DEALER DID NOT REPAIR THE VEHICLE BECAUSE THE STATUTE TO RECEIVE THE RECALL REPAIR WAS EXPIRED. THE DEALER AND THE MANUFACTURER REFUSED TO COVER THE RECALL REPAIR. THE CONTACT WAS INFORMED TO REPLACE THE REAR AXLE DUE TO THE MIS-INSTALLATION OF THE BRACKETS. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 10V385000 (SUSPENSION), AND NHTSA ACTION NUMBERS: EA10007 (SUSPENSION AND STRUCTURE) AND PE10006 (SUSPENSION). THE FAILURE MILEAGE WAS NOT AVAILABLE.

RH BACK SIDE OF SUBFRAME, IS ROTTED/CORRODED SO BAD THAT THE METAL TORE ALL AROUND THE SUBFRAME BUSHING. TO WHERE IT IS NOT BEING HELD UP BY THE BUSHING ON THE RIGHT HAND LOWER/BACK IS NOT HOLDING UP THE FRONT SUBFRAME... NOW, THE VEHICLE IS MAKING A VERY LOUD POPPING NOISE WHEN DRIVING AND TURNING... AND WHEN TURNING FAST ENOUGH (MORE TURNING LEFT THEN RIGHT) CAN FEEL WHOLE FRONT END JERK LIKE ITS ABOUT TO GO THE OPPOSITE WAY THE VAN...REPLACED THE LEFT FRONT STRUT ASSEMBLY AND CONTROL ARM TO FIND OUT THAT DID NOT SOLVE THE PROBLEM. THEN AFTER REPAIRS AND LOOKING DEEPER.. NOTICED RIGHT FRONT SIDE, SAGGING ALMOST 2-4 INCHES LOWER THEN LEFT FRONT... THAT'S WHEN WE NOTICED THE SUBFRAME COMPLETELY BROKEN/RUSTED OFF FROM THE BODY BUSHING (ON THE FRONT RIGHT LOWER/REAR BUSHING)

THE SWEIGH BAR LINKS HAVE BEEN REPLACED TWICE. BREAKS AND ROSTERS TOO! THE TIRES ARE NEW WITH INLINEMENT AND ROTATION DONE! I HAVE WENT THROUGH SEVERAL SETS OF TIRES! THE VEHICLE JUST DOESN'T DRIVE CORRECTLY! THE VEHICLE IS ALSO MISSING WITH NO FOUND REASON AND WILL RANDOMLY DIE! IT FEELS VERY LOSE AND UNSAFE ON THE ROAD! THE COIL PACK, PLUGS AND PLUG WIRES REPLACED! ALL NEW FLUIDS INCLUDING ANTIFREEZE, BREAK FLUID, POWER STEERING FLUID, OIL AND TRANSMISSION FLUID! THE AIR FILTER AND OTHER FILTERS! NEW FUEL PUMP AND IT'S STILL NOT RIGHT! BREAK LIGHT COMES ON AND OFF AND EMERGENCY BREAK ISN'T SET NOR IS IT LOW ON FLUID! NEW BREAKS AND CALIBER AND ROTOR! SERIOUSLY HAVE INVESTED SLOT OF MONEY IN THIS VEHICLE! ALSO MOTOR FOR WINDOWS BEING REPLACED NOW! GAGE HAND WILL PERIODICALLY GO ALL THE WAY TO THE RIGHT THE AFTER A FEW SECONDS GO BACK...

FORD HAD PUT THE BRACKETS ON THE REAR AXLE. THESE FAILED. REAR AXLE CRACKED. ALMOST CAUSING MY FAMILY TO CRASH INTO TREE

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. IN 2010, THE DEALER REPAIRED THE VEHICLE PER NHTSA CAMPAIGN NUMBER: 15V608000 (SUSPENSION) CONCERNING THE REINFORCEMENT BRACKETS. WHILE DRIVING APPROXIMATELY 65 MPH, THE REAR AXLE FRACTURED AND THE REAR DRIVER SIDE TIRE BLEW OUT. THE CONTACT WAS ABLE TO COAST THE VEHICLE OVER TO THE SIDE OF THE ROAD. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THERE WAS EXTENSIVE RUST AND CORROSION AND THE REAR AXLE NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.

DRIVING ON HWY 49 DRIVING APPROXIMATELY 40 MPH WHEN I LOST CONTROL WITH MY CHILDREN IN THE CAR. LUCKILY WE CAME TO A STOP OFF THE HWY. I COULD SEE MY TIRE WAS ALMOST SIDEWAYS AND BLOWN. MY FINANCE PICKED US UP AND SAID THE AXLE HAD SNAPPED AND TOOK A PICTURE. IT IS SATURDAY AND I'M WITHOUT A CAR. I FOUND OUT THIS WAS RECALLED. I JUST WANT TO MAKE SURE FORD WILL FIX THE ISSUE AND IN A TIMELY MANNER SINCE I HAVE NO OTHER CAR.

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V030000 (STRUCTURE). THE VEHICLE WAS REPAIRED; HOWEVER, THE VEHICLE FAILED THE ANNUAL SAFETY INSPECTION. THE SAFETY INSPECTOR DIAGNOSED THAT THE SUBFRAME AND BUSHINGS FRACTURED. THE VEHICLE WAS DRIVEN TO A COLLISION SHOP WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS CRACKED. THE VEHICLE WAS DELIVERED TO THE DEALER, BUT NOT DIAGNOSED NOR REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 170,000. UPDATED 10/04/16*LJ *TR

HUSBAND WAS GOING TO WORK IN EARLY MORNING AND HAD JUST SLOWED AS HE EXITED HIGHWAY, WENT OVER FIRST SET OF RAILROAD TRACKS AT SPEED LIMIT, THEN THE FRONT END OF VAN RAISED INTO THE AIR ABOUT A FOOT THEN SLAMMED DOWN AS HE CROSSED THE SECOND SET OF TRACKS AND HE LOST CONTROL. HE HAD NO BRAKES OR STEERING AND THE VAN CRASHED INTO A CURB BEFORE STOPPING. IT NARROWLY MISSED GOING UNDER A SEMI-TRUCK. IT TOOK SEVERAL HOURS TO BE TOWED TO FORD DEALER AND MISSING AN UNPAID DAY OF WORK, OUR INSURANCE SECURED A RENTAL CAR SINCE FORD REFUSED TO DO SO. THE 2002 WINDSTAR HAD BEEN PREVIOUSLY REPAIRED UNDER THE 2011 REAR AXLE RECALL 10S13 AND SUBFRAME 11S16 PASSED INSPECTION AT THAT TIME, BUT BOTH APPEARED TO HAVE FAILED IN THIS INSTANCE. THIS FAILURE CAUSED OVER $3000 IN COLLATERAL DAMAGE TO THE STEERING AND EXHAUST SYSTEMS...

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE AT AN INSPECTION LOCATION, THE MECHANIC DIAGNOSED THAT THE FRONT PASSENGER'S SIDE SUB FRAME HAD FRACTURED DUE TO CORROSION AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN NUMBER: 11V030000 (STRUCTURE). THE FAILURE MILEAGE WAS 40,000.

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING AT 20 MPH, THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER. THE VEHICLE HAD A FRONT END ALIGNMENT AND OTHER REPAIRS PERFORMED BUT THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SUB FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000. UPDATED 04/14/16*LJ THE CONSUMER STATED THE SUBFRAME WAS COMPLETED CORRODED. *JS

THEY HAD A RECALL IN 2011 WHERE THEY PUT SUPPORT BRACKETS ON THE REAR AXLES. MINE DID HAVE THE BRACKETS PUT ON AND RIGHT BEHIND THE BRACKET THE AXLE STILL BROKE DRIVING DOWN THE STREET AT 40 MPH WHERE WE ALMOST HIT ANOTHER CAR WITH CHILDREN INSIDE HER AND MY VEHICLE. FORD SAID THE BRACKETS ARE ONLY WARRANTIED FOR 12 MONTHS. THESE VANS DO NOT NEED BRACKETS THEY NEED NEW AXLES. *TR

WHEN BRINGING MY WINDSTAR IN FOR AN ALIGNMENT IT WAS FOUND THAT THE SUBFRAME HAD ROTTED AND CRACKED NEAR THE CONTROL ARM. FORD HAD "COMPLETED" THE NECESSARY REPAIRS TO ADDRESS THIS ISSUE AND HAS STATED THAT THEY ARE NOT RESPONSIBLE FOR THE DAMAGE TO THE VEHICLE EVEN THOUGH IT WAS THE ORIGINAL REASON FOR THE RECALL. ACCORDING TO THE INFORMATION FROM THE ORIGINAL RECALL FORD WAS SUPPOSED TO REPLACE THE SUBFRAME HOWEVER SMALL BRACKETS WERE ADDED TO THE VAN INSTEAD. I DO NOT FEEL THAT THE RECALL WAS PROPERLY DONE BY FORD. *TR

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING AT UNKNOWN SPEEDS, THE DRIVER HIT A BUMP IN THE ROAD AND THE VEHICLE MADE A CRACKING NOISE. UPON INSPECTION, IT WAS FOUND THAT THE PASSENGER REAR WHEEL WELL WAS DAMAGED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 166,000.

WE WERE SLOWING TO PULL UP TO OUR HOME. WE WERE DRIVING ABOUT 10 MPH. ABOUT 70 FEET FROM OUR HOME. IT SOUNDED LIKE THERE WAS A FLAT TIRE WITH RUBBING AND BUMPING NOISES. WE PARKED ON THE STREET IN FRONT OF OUR HOME. UPON INSPECTING THE VEHICLE, THE TIRES WERE INTACT. THE TIRES ARE BOWING IN. WE LOOKED UNDER THE REAR OF THE CAR. WE SAW A LARGE CRACK OF THE REAR AXLE CLOSER TO THE DRIVER'S SIDE OF THE CAR. FORD RECALLED THE REAR AXLE FOR THIS VERY REASON 3 YEARS AGO DUE TO CORROSION CAUSED BY YEARS OF EXPOSURE TO SALTED ROADS. FORD PERFORMED THE RECALL WORK BY PLACING A BRACKET ON THE AXLE. THE BRAKE ON OUR AXLE OCCURRED UNDER THE BRACKET. FORD IS NOT ASSUMING RESPONSIBILITY EVEN THOUGH THE SUPPORTS THEY PLACED ON THE AXLE FAILED TO DO THEIR JOB. THERE ARE OTHER COMPLAINTS THIS...

SLIDING SIDE DOORS AND REAR WHEEL WELLS RUSTING FROM BOTTOM UP. THERE IS A DRAMATIC AMOUNT OF RUST. WORRIED ABOUT STRUCTURAL INTEGRITY OF DOORS IN CASE OF A SIDE-ON COLLISION. THIS IS TRUE FOR BOTH THE WINDSTAR AND FREESTAR. *TR

REAR AXLE BROKE IN HALF AS I WAS TURNING A CORNER AT VERY LOW SPEED, CAUSING TO LOOSE CONTROL OF VEHICLE AND RUN OFF ROAD. *TR

ATTEMPTED TO CHANGE LANES, MOTORIST FROM BEHIND SPED UP, APPLIED BRAKES, ABS LIGHTS FLASHED ON DASH, CAR DID NOT SLOW, PRESSED BRAKES HARDER AND REAR BRAKES LOCKED UP, CAUSING ME TO SIDE SWIPE GUARD RAIL. *TR ABS LIGHTS AND BRAKE LIGHTS HAVE REMAINED ON FOR OVER 2 YEARS. HAVE SPEND THOUSANDS OF DOLLARS ATTEMPTING TO REPAIR THIS PROBLEM, TO NO AVAIL. BRAKES ARE INTERMITTENT AT BEST. ABS AND BRAKE LIGHTS ARE STILL ON.

ABS BRAKE LIGHTS ON, AFTER RESEARCH, ITS A COMMON PROBLEM WITH FAULTY ABS MODULES. SUBFRAME IS ROTTING OUT WITH THE MOUNTING POINTS OF THE SUBFRAME PEELING AWAY. O/D LIGHT COMING ON INTERMITTENTLY, AFTER RESEARCH, COMMON PROBLEM POINTS BACK TO A BAD VEHICLE SPEED SENSOR. MILEAGE DOES NOT SEEM TO BE A FACTOR. FAULTY HARD LINES FOR REAR HEATING. MULTIPLE CRACKS IN LINES CAUSE RADIATOR FLUID LOSS. VERY VERY COMMON PROBLEM, LOOKED AT 10-15 WINDSTARS IN PULL-A-PARTS LOT, ALL WITH FAULTY HARD LINES. *TR

RIGHT REAR WHEEL WELL BODY PANEL ROTTED A HOLE THAT EXTENDS INTO THE SLIDING DOOR ROLLER AREA AND INTERIOR TO THE SEALS OF THE VEHICLE. WHILE THIS HAS NOT CAUSED AN ACCIDENT, I AM CONCERNED ABOUT THE INTEGRITY OF THE SLIDING DOOR AND PROTRUSION INTO THE PASSENGER CABIN. *TR

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE VEHICLE WAS INCLUDED IN THE RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 11V030000 (STRUCTURE: FRAME AND MEMBERS: UNDERBODY SHIELDS) AND WAS REPAIRED. AFTER THE REPAIR, THE CONTACT HEARD A BANGING NOISE IN THE FRONT END OF THE VEHICLE WHILE DRIVING APPROXIMATELY 35 MPH. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE CONTROL ARM WAS DETACHED FROM THE SUB FRAME AND THAT THE SUB FRAME WAS CORRODED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THE CONTACT THAT THE REPAIR WAS NOT COVERED UNDER THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 126,000.

WHILE DRIVING MY 2002 FORD WINDSTAR I STARTED TO HEAR A GRINDING SOUND AND COULD TELL SOMETHING WAS WRONG AND HAD TO PULL OVER. I WAS DRIVING AT A LOW SPEED AT THE TIME FORTUNATELY. IT ENDED UP BEING THAT THE REAR AXEL BROKE. THE MECHANIC INDICATED IT APPEARED TO HAVE RUSTED FROM THE INSIDE OUT. THANKFULLY THIS HAPPENED 2 DAYS AFTER A RETURN FROM VACATION AT WHICH TIME WE WERE TRAVELING 70+ MPH ON THE WEST VIRGINIA TURNPIKE. *TR

TL*THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING AT SPEEDS OF 30 MPH, SHE HEARD AN UNUSUAL BANGING NOISE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE SHE WAS ADVISED THAT THE MAIN BEAM HAD FRACTURED. THE MECHANIC PERFORMED THE NECESSARY REPAIRS BY WELDING THE BEAM SECURELY TO THE VEHICLE. THE MANUFACTURER STATED THAT THERE WERE NO RECALLS ON HER VEHICLE. THE FAILURE AND CURRENT MILEAGES WERE 119,500.

WHEN DRIVING MY 2002 FORD WINDSTAR MINI VAN ON THE HIGHWAY WE NOTICED A LOUD SLAMMING NOISE FROM THE REAR CAUSING THE VEHICLE TO LOSE CONTROL, SWERVING TO THE RIGHT SHOULDER AND STALLING WITH THE TAIL END STILL IN THE MIDDLE OF THE TWO LANE HIGHWAY, AS THE TRACTOR TRAILER BEHIND US WHO WAS VERY ALERT NEARLY MISSED A REAR END COLLISION WITH OUR VEHICLE. UPON INSPECTION OF THE UNDERSIDE OF THE VEHICLE WE NOTICED THE REAR AXLE BEAM WAS SPLIT IN TWO, RUSTED AND ROTTED OUT AND HANGING TO THE GROUND, A TOW TRUCK WAS NOTIFIED AND THE OPERATOR STARED IN DISBELIEF THAT THE AXLE HAD BROKEN IN HALF. THIS OBVIOUS DEFECT COULD HAVE COST US OUR LIVES. THIS DEFECT NEEDS TO BE ADDRESSED IMMEDIATELY BEFORE A SOME LIVES ARE LOST AS A RESULT OF THE FORD WINDSTAR REAR AXLE BEAM BREAKING WHILE OCCUPANTS AND PASSENGERS ARE RIDING IN...