Frame Rust problems of the 1999 Ford Windstar - part 2

After a couple of inspections and lots of clunking noises and alignment issues, my mechanic (and a mechanic from another shop) suggested strongly that I replace the vehicle's subframe/engine cradle. The frame was rusting/rotting from the inside out at both front ends near and around the motor mounts and the subframe bolts (attaching to the unibody frame). There was also some rot occurring below the area that a/c water condensation drips. The frame was replaced soon after . . . Avoiding driving the vehicle until repair was made. Unfortunately, the old part was tossed before I could ask the mechanic to save it for me.

The lancaster Ford dealer performed a recall on the rear axle subframe rust issue in a satisfactory manner. However the left side rocker panel was rusted but they didn't replace it. Now it is completely gone. I am writing to see if Ford replaced the rocker panels also.

My sisters 1999 Windstar had a rusted subframe. I took my 1999 Windstar to a mechanic , the subframe was starting to rust on the right side. Within 4 weeks , the frame split while driving with my 2 kids in the car. It is undrivable. I call Ford on 7/22/09 to let them know of a design problem (the a/c draintube drains on the subframe on the right. There is no other rust on the car, but Ford said my car was out of warranty and there is nothing they can do. Its not a warranty issue, its a design issue. I am having it fixed and I think Ford should reimburse me . They will need to replace the subframe.

1999 Ford Windstar - subframe rusted out. Had repairs done. Had vehicle inspected by Ford for current rear axle recall, was told there was no rust in the rear axle. I am having the car inspected by my mechanic because it would seem that if the front end rusted out, so would the back.

We have a 99 Windstar with a broken engine cradle. My wife was driving the van along with my son to a local retailer. She was in the middle lane when she heard a loud bang under the van. My son who was sitting ton the passenger side said he felt it under his feet. She was able to get the van to the side of the road even though the steering was very difficult. She was about 5 miles from home so decided to take it back home. Surprisingly she was able to get it home. I crawled under the unit and immediately saw that the engine cradle had snapped on the passenger side rear. It was then that we stopped driving the van due to safety concerns. I did some research on the web and they were several complaints identical to ours. It seems that the ac drain hose is situated over the exact location of the break. Apparently over a period of time this causes the frame to rust out. I called Ford to complain and they said that there was nothing they could do. I called my local Ford dealer and passed on buying a new part due to the cost. I had to take a day off from work and go junkyard shopping to find a replacement part. I located one and we had the unit towed to lucas Ford in burlington, n. J. Where my wife works part time. The part was delivered and the dealer did the replacement along with a bad rack and pinion unit that was discovered at the same time. The unit had 77,817 on the odometer at the time the work was done. I can understand mechanical items going bad but this was a structural item. This situation could have been so much worse say had she been on the interstate doing 65 mph instead of on a local road doing 40 mph. I could see if this was an isolated incident but it isn't. I contacted Ford one more time and complained again to no avail. I have always owned Fords and probably always will but this experience along with one I had concerning my 1985 thunderbird control module has left a bad taste in my mouth as to how they take care of their customers.

The front subframe rusted through on back passenger side. The rest of the vehicle is rust free for the most part. The car has 80,300 mi . Its a 1999 Ford Windstar.

While driving my 1999 Ford Windstar, I heard a thump coming from the passenger side front end. I then felt the steering wheel go from the 12 o'clock position to the 3 o'clock position. I stopped the minivan and got out to inspect the under carriage. I found that the subframe on the right passenger side rusted through a few inches from where it bolts to the vehicle. The vehicle s no longer safe and is currently at the repair shop being inspected. I was told by the technician that he has never seen a subframe rust through as it did. The vehicle has one owner and is well maintained. Pictures available at request.

Started hearing a funny noise (rubbing or squeaking) on the passenger side of vehicle (1999 Ford Windstar). Mechanic showed me where the sub-frame has rusted and spit apart. The front end of the car is literally separating from the back end. He said he has never seen this happen and recommended that I call Ford. Ford was no help at all. Said "sorry", but there was nothing they could do. Made no effort whatsoever to fix this safety issue. There was no accident with this, but there definitely would have been if I continued driving this.

Hi I just saw that you were investigating Windstar rust issues. Two years ago, in 2008, our 1999 Windstar starting making weird noises when I went over curbs or turned the wheel. I took it into the dealer and they said the front frame and axle had rusted. It was a couple thousand dollars to fix. They said it was no longer under warranty. I did not wish to fix it (since it would cost as much to fix as the van was worth) and they said it was unsafe to drive and did not recommend I leave without fixing it. So we traded it in (explaining fully what was wrong with it) when we purchased a van from the Honda dealership down the road. I just saw that you were investigating rust issues associated with Windstars and thought I would pass this info along. Thanks.

1999 Ford Windstar subframe rusting and having to be replaced. Van failed safety inspection because of a hole in subframe due to rust. Total cost paid out of pocket in 2008 $1240. 56.