Body problems of the 2001 Ford Windstar - part 1

Rear axle cracked in multiple locations causes car to sway and tires to turn inward and bald.

Car was in an single car accident. Steering and body damage. All fixed now. Need verification for salvage sticker.

The axle was part of recall #11s16. As part of the recall the axle was patched, but the axle is now broken because the "repair" did not correct the structural flaws in the axle.

When I received the recall about the possible axle cracking due rust I took my car in and had the brackets put on and then I received a recall the have the brackets checked which I did and they were correct. Today I took my van in for PA inspection and was told my rear axle on the drivers side had a crack in it which you could see through the opening of the bracket they installed. When I asked the mechanic if Ford was going to pay to replace it now since the bracket didn't keep it from cracking he said no. Then I asked if the bracket was strong enough to hold it so I can keep driving, he said he wouldn't trust it. I only have a 115,500 miles on it, so what I'm basically being told is the minute the recall went out I should have had them replace the axle, instead of the stupid brackets which were just band aids to placate upset owners. I only have one car so I have to drive it until I can afford to get it fixed or buy another car. I'm just one person, how many more are faced with the same situation. I only have until October when my inspection expires and I'm panicking trying to figure what I can do. Ford knew those bracket s at best just bought the owners a couple of more years before their cars could again be a highway hazard. It's still russian roulette in my opinion the axle at a minimum should be replace with a discount to the original owners.

1. Rear axle fractured severely & broke making the car un-drivable on 24 Jan 2019 while in motion driving in city traffic. Ford put braces on this vehicle under recall# 10s13, but they failed to prevent further corrosion and metal fatigue. The axle was a bad engineering design from the drawing board combined with not e-coating the metal during manufacturing to prevent corrosion of the metal due to road salt. The axle fractured next to the brace on the driver side as shown in the 4 images below. I have one tow bill (flat-bed) to get the car off the downtown street to my home & will have another tow bill to transport it to where I can replace the axle. 2. Front cradle frame's mount rusted off that anchors the stabilizer bar so the stabilizer bar had to be removed. This happened several years ago. The cradle frame probable was not e-coated during manufacture either. I can take a pic and probable have the repair invoice detailing the date and the mechanic's work to remove the stabilizer bar. To fix the car will need a new front cradle frame, stabilizer bar, and possibly mount brackets.

This van was recalled for known issues with the rear axle corroding. This recall involved installing support brackets on the axle. The axle has now cracked almost all the way through next to the bracket. This happened while going over a speed bump slowly. From my research online, this seems to be a common issue with the repair that was issued in this recall.

Removed subframe to replace faulty torque converter. Found substantial rusting at firewall end of subframe on both "arms", requiring replacement of subframe. Called local dealers, no "open" recall (over 15 year-old van) and $4,900 new subframe quote provided, with no dealer or manufacturer coverage, after calling national and canadian mfctr recall numbers. Mfctr/dealers of no assistance, whatsoever. Part not actually available.

Sub frame.

I was driving at around 30 mph, 2 cars in front slammed on brakes, I was approximately 1 1/2 car links back and hit the brakes. Abs failed, airbags failed, and slid into car in front of me. I was on a city street going straight.

The contact owns a 2001 Ford Windstar. While driving 5 mph, the subframe completely fractured and fell apart without warning. The vehicle was towed to an independent mechanic (spielmann service center mn; 952-546-0508) where it was confirmed that Ford would not pay for the damage. The vehicle was towed to the dealer (luther north country Ford, located at 10401 woodcrest dr NW, coon rapids, mn 55433; (612) 424-7648) where it was diagnosed that the engine, transmission, and drive train needed to be replaced. The vehicle was not repaired. The manufacturer was contacted at 800-392-3673 and stated that only the subframe could be repaired for free, but the damage for the engine, transmission, and drive train would have to be paid for by the contact. A case number was not provided. The approximate failure mileage was 184,500.

Takata infiators;I Ford denying my request f VIN #2fmda584x1bc09440 I have an obvious crack (see photos) directly under the bracket a band-aid that Ford issued in an earlier recall on my rear axle with the sole purpose of this band-aid to prevent such cracking. Apparently my bracket part was deemed installed correctly, effectively causing a denial for a replacement part on my Windstar. Clearly this bracket failed and did not stop my rear axle from experiencing cracking! Ford clearly new exactly where this cracking would occur because the crack appears directly under the bracket installed to create a stronger part. The only thing holding this rear axle together is this bracket. This particular part in question is directly below the gas tank, should this crucial part experience failure while driving on a 70mph highway what would happen? also looking at my Windstar on a lift we noticed the center of the Windstar seems to be sagging (see photos) from what appears to be the under carriage breaking down from rust and corrosion, this appears to be causing extreme structure failure. I do reside in one of the stated salt belt states as being the state of iowa. What would the full criteria for this recall and buyback program on certain Windstar's in 2011 thru 2013 be? why was my Windstar limited excluded in this recall? I still have not been advised not to drive my Windstar by any current Ford representatives. However former Ford mechanics have advised me not to drive my Windstar, these same mechanics� are adamant my Windstar is unsafe! I have been attempting to fix the concerns that moffitts Ford in boone iowa wanted me to repair at the time of the axle inspection. Only having more concern brought to my attention about the axle. I wrote mr. Fields a letter 2/15/17 asking to overturn and allow repair kathleen colpoys 515-230-1430 po box 574 clinton IA, 52733.

The contact owns a 2001 Ford Windstar. While a rack and pinion was being installed on the vehicle, the contact was informed by the service technician that the subframe was corroded. The vehicle was previously repaired per NHTSA campaign number: 11v030000 (structure), but the remedy failed to repair the vehicle. The contact mentioned that the previous repair was not adequate. The manufacturer was notified of the failure. The failure mileage was unknown.

The contact owns a 2001 Ford Windstar. The contact received notification of NHTSA campaign number: 15v608000 (structure). The vehicle was taken to the dealer who indicated that the brackets were installed properly, but failed to provide a correct diagnosis. The contact stated that the tire rubbed against the frame in the rear and fractured the rear driver's side bracket. The vehicle was parked at the contact's residence due to the failure. The dealer was notified of the failure. The manufacturer was notified. The failure mileage was unknown. Parts distribution disconnect.

The contact owns a 2001 Ford Windstar. While operating the vehicle, a clunking noise was heard coming from the front of the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the cradle mount fractured due to corrosion and rusting. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 120,000.

Hoping they have a repair for the subframe passenger rear mine is badly rotted and afraid to drive it as it can cause a major accident or be possibly hazardous Ford please cure this.

The contact owns a 2001 Ford Windstar. While driving approximately 30 mph, the front end frame fractured and disengaged from the vehicle. The vehicle was taken to the dealer where it was diagnosed that the shock absorber, front end spring, and frame were fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 100,000.

The contact owns a 2001 Ford Windstar. The dealer (russ milne Ford, 24777 hall rd, macomb, mi 48042, (877) 821-8648) indicated that a recall remedy was provided for the replacement brackets before the contact owned the vehicle. Within a year of owning the vehicle, the failure recurred. The manufacturer was notified of the failure and stated that a recall had already been provided. Although the contact informed the manufacturer that the recall remedy failed to correct the failure, they stated that the contact would need to repair the vehicle. In addition, the engine cradle was completely rusted to the point of fracturing, causing shaking and a strong vibration. The failure mileage was not available.

Tl- the contact owns a 2001 Ford Windstar. The contact stated that while driving at various speeds a knocking noise was present coming from the front passenger side of the vehicle. The vehicle was taken to the dealer who diagnosed that the frame engine cross member was corroded. The contact was informed by the dealer that the remedy for NHTSA recall campaign number 11v03000 was performed approximately 4 years ago. The contact indicated that the vehicle had experienced additional failures related to the recall. The manufacturer was notified of the failure. The failure mileage was 61,400. Jft.

The contact owns a 2001 Ford Windstar. The contact stated that the dealer (gurley leep Ford Lincoln, 320 e ireland rd, south bend, in 46614, (574) 291-6910) indicated that they serviced an unknown recall from the manufacturer for the reinforcement brackets and that they had not been required to provide any additional repairs. The dealer replaced the rear axles due to the reinforcement brackets fracturing while the vehicle was being driven below 25 mph. The dealer stated that they were not required by the manufacturer to reinstall reinforcement brackets. The manufacturer was notified of the failure and suggested replacing the same oem rear axles. The vehicle was repaired. The failure mileage was not available.

In March 2015, I reported to Ford that the rear axle broke in half while driving. We had been driving down the interstate 10 minutes before going 70 mph. If it had broken then, my husband and two daughters (13, 15) would have most certainly been killed. However, god spared us because we were only going 30 mph on a side street when the axle failed. When I reported it, Ford told me that the rear axle recall ( I had performed in 2012) warranty had expired. Also, any private mechanics I approached said it was a Ford recall and would not perform the repair. So, at 137,000 miles we junked the vehicle at a junk yard because we couldn't get it repaired.

In 2011 Ford recalled over 400000 vans (1997-2003) due to serious corrosion of axles and other components. Special repairs were done at Ford expense. Recently my mechanic informed me that the rear motor mount and the van sub frame had continued to rust badly to the extent that the unit was a safety risk. A search of the internet indicates that many, many repaired Ford vehicles have experienced very serious corrosion of the sub frames and the repaired axles with serious results including failure of sub frames and or axles when driving!!.

Tl-the contact owns a 2001 Ford Windstar. The contact stated that while the vehicle was being serviced, the independent mechanic discovered that the rear and front sub frame was severely corroded. In addition, the front sub frame exhibited a hole on the driver¿s side and the rear axle was fractured. The vehicle was repaired under NHTSA campaign number: 11v030000 (structure) but the sub frames were not repaired. The manufacturer was made aware of the failure. The failure mileage was 91,120. Djr.

The rear axle broke in the place that was "fixed" by the recall work in 2010. Noticed squeaking noises (tire was rubbing) and a large clunk and wiggle when turning into a parking lot. Took a photo when I got to the parking lot. My rear driver's side tire was at an angle to the vehicle and the rear axle was broken under the collar that had been attached by a dealer for the recall. The weld held up, but the axle snapped underneath the fix-up job. Apparently the recall fix wasn't really a fix. Towed it into a dealer, who took photos and talked to Ford. Ford said they wouldn't do anything. Cost me $$ to tow it to the dealer and back home again. Don't have $1,000 to pay the dealer for a new rear axle. Very disappointed that they didn't stand by their work. Very thankful that I was not on the freeway, and that all my children were not with me at the time. It could have been so much worse!.

I was driving on interstate 39 towards wisconsin dells with my wife and daughters. About 15 miles out of madison wisconsin my daughters began screaming I looked back and there was smoke everywhere. I immediately pulled to side of highway and got everyone out of the vehicle. Both my rear tires had collapse. I had to get towed into a Ford dealer in madison wisconsin. The rear axle on the van had split in half. Calling Ford was no help. They stated that a recall had been on that vehicle a couple years back and that the warranty on that recall had expired. Luckily nothing happened to my family but if these issues on this recall which was done two years ago hasn't fixed the problem someone is going to get seriously hurt! even if I fix this problem I will not be able to trust this vehicle. Please look into this someone. There are many Windstars that were repaired around the same time because of recall that will begin to fall apart again. Problem not fixed!.

The contact owns a 2001 Ford Windstar. The contact stated that while attempting to shift into drive, the frame became fractured and the engine detached from the vehicle. The vehicle was taken to the dealer where the technician verified that the sub frame was fractured and needed to be replaced. The manufacturer was made aware of the failure but did not offer any assistance. The vehicle was not repaired. The failure and current mileage was 95,000.

Tl-the contact owns a 2001 Ford Windstar. The contact stated that while driving at 55 mph on cruise control and trying to make a turn, the vehicle proceeded to keep straight without warning and the vehicle caught fire. A fire report was filed. The fire department extinguished the fire. The vehicle was not destroyed. The manufacturer was not notified of the failure. The failure mileage was approximately 100,000. Djr.

The contact owns a 2001 Ford Windstar. The contact stated the vehicle was taken to an independent mechanic for an inspection. The technician informed the front portion of the frame was completely rusted. There was a recall associated with NHTSA campaign id number 11v030000 (structure: frame and members:underbody shields); however the VIN was ineligible. In addition, the vehicle was not originally sold or registered in the states mentioned in the recall defect. The vehicle had not been repaired. The manufacturer was notified of the problem. The approximate failure mileage was 120,000.

At a major intersection getting onto a highway our subframe gave out and we came to a screeching halt & a dead stop. The entire subframe under the passengers side of the van rotted and the wheel was up against the frame of the car. It could have caused a major accident. It cost us $1,500. 00.

The contact owns a 2001 Ford Windstar. The contact stated that while turning right into a parking space, a loud clunking noise was heard. The vehicle was taken to the dealer who diagnosed that the front sub frame was corroded and needed to be repaired. The manufacturer was made aware of the failure who did not offer any assistance since there were no recalls related to the failure. The vehicle was not repaired. The failure mileage was 167,500 and current mileage was 168,000.

Annual state inspection found rust at mount on right front subframe,,passenger rear rocker panel has rust hole. Abs/brake lights stay on,even after they been fixed.

The contact owns a 2001 Ford Windstar. The contact stated the vehicle was repaired under the recall associated with NHTSA campaign id number 11v030000 (structure: frame and members:underbody shields). Upon having the repairs completed, the contact was informed that the front sway bar link also needed to be replaced due to excessive corrosion, but were not included in the recall. No additional repairs were performed. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 156,503. Updated 11/03/11.

The contact owns a 2001 Ford Windstar. The contact stated that the frame was severely corroded underneath the vehicle near the sliding doors and rocker panels. As a result, there was not place to support the universal jack. The vehicle was taken to an independent mechanic, who inspected the vehicle and confirmed that the frame and the areas near the rocker panels were corroded. The dealer was not notified. The manufacturer was not notified. The failure mileage was 230,000.

Tl- the contact owns a 2001 Ford Windstar. The contact stated that he was driving the vehicle and stated that he heard a noise underneath the vehicle. The vehicle was taken to the dealer for inspection and they stated that the sub frame of the front passenger side of the vehicle needed to be replaced because it was corroded. The vehicle was repaired but the failure recurred. The manufacturer was notified and they stated that the vehicle was already repaired under recall NHTSA campaign id number: 11v030000 (structure: frame and members:under body shields), and that he would have to pay for the repair. The failure mileage was 142,023. Ap.

I have a 2001 Ford Windstar that was serviced for the safety recall 11s16,(11v030000 NHTSA campaign number) 04/11/2011. My vehicle was grounded do to significant subframe rot but it was deemed repairable by Ford. On February 2, 2013 I noticed a 2 inch long crack/perforation on the top part of the sub-frame where the repair bracket was attached when I was rotating the tires. I took it back to the Ford dealership and they said they were unable to help because it was repaired once and they wont pay to have it repaired again. Im not sure if they missed this the first time it was fixed or what. I do know that according to Ford's specs for determining if a subframe is repairable or not this crack would deem in non-repairable because its within the 2 inch mark from the tooling hole. Now im just waiting for the subframe to completely crack while im driving down the road. The repair bracket that was supposed to solve the problem to begin with will not hold the subframe together if it completely cracks at the spot at which its located in. I also believe that due to downward force on the subframe body mount and the fact where the u shaped bracket is sitting on the subframe that holds the bracket on the subframe, it is acting like a fulcrum point where the subframe is bending and cracking.

My '01 Windstar had subframe repair in spring 2011. . . Was said to be " inspect subframe- did not pass but can be repaired". It was repaired at that time. Last week, I had it into a mechanic for an unrelated problem where he had it on the lift. He told me that the subframe is "completely rotted". I currently plan to return to Ford dealer. . . Updated 04/16/12.