Eight problems related to frame and members have been reported for the 1996 Ford Windstar. The most recently reported issues are listed below.
The dealership noticed a crack in the sub frame. Which could had caused the engine to fall out, if the vehicle was in an accident.
Consumer heard a noise coming from lower passenger's side of vehicle. After inspecting vehicle dealer determined subframe was cracked.
The sub-frame broke where the strut arm connects in the front( in area of the strut arm bushings. At first thought that the noise was from at loose heat shield. Strut arm rattles everytime van iecounters rough pavement. The speedometer just went haywire. Needle bounces all over the place. Have found other people on the internet with the same speedometer problem. I feel that both of these failures are a saftey issue. Ford motor doesn't.
Had just pulled out onto the street then heard a snap. Checked , and noticed left rear wheel had kicked out sideways and was hitting the mud flap. Rear frame holding rear axle had broken in half. Rear axle needed to be strapped up before vehicle was towed to dealership.
Trailing arm attached to the body of rear axle fractured while driving at low speed. No evidence of any impact to the trailing arm or body of the rear axle. Dealer / manufacturer notified, and informed consumer that warranty expired, and vehicle was not covered under a recall.
A popping noise was coming from the front end. Four bolts and mounts attached to the frame had deteriorated and needed to be replaced. Ford manufacturer states the vehicle was out of warranty and cannot duplicate the problem.
The front frame of the vehicle was loose.
The front subframe bushing rotted / corroded. Dealer has been contacted.