Frame And Members problems of the 2002 Ford Windstar

The contact owns a 2002 Ford Windstar. The contact received notifications of NHTSA campaign numbers: 11v030000 (structure) and 15v608000 (suspension). The contact stated that while approaching a traffic signal and driving slowly, the vehicle shook, and the engine shifted. The contact stated that the engine shifted to the right. In addition, the contact lost control of the steering wheel. The contact stated that the rpms became elevated. The contact pulled over into a parking lot and turned off the vehicle. The contact exited the vehicle, and upon inspection, became aware that the subframe had detached and was dragging. The contact believed that the motor mounts were fractured. The vehicle was towed to a tow yard. The vehicle was not taken to the dealer or an independent mechanic, and the vehicle was not repaired. The vehicle remained at the tow yard unrepaired. The manufacturer was made aware of the failure and referred the contact to the nhsta hotline to report the failure. The approximate failure mileage was 108,000.

The contact owns a 2002 Ford Windstar. The contact received notification of recall number:11v030000 (structure: frame and members:underbody shields) and took the vehicle to the dealer; however, the entire mount was covered with rust and the recall repair did not correct the failure. The dealer advised him that they were only responsible for what was indicated in the recall and offered no further assistance. The manufacturer was aware of the failure. No repairs were performed. The current and failure mileages were 130,000.

Backing out of the driveway there was a horrible sound, like the brakes sticking. Employee got out & the tire was cut completely around. The estimate is $900 to replace the springs & struts on both sides. I feel this is directly linked to the investigation & findings of the salt belt corrosion issues, but there is no recall for the specific components effected on the vehicle.

While driving our van first seemed to be pulling in the back to the right (rear passenger side. My husband inspected the tire and thought maybe we need to get new tires soon. It seemed to be somewhat drivable when we were on the dry pavement, but we have alot of snow covered roads as well and on these the vehicle was almost completely unmanageable. It was constantly fishtailing the whole way down our snow covered rural road. When we finally got home, my husband pulled it into the garage. Right away he noticed the rear passenger side wheel was turned inward, which had not been visible a few hours earlier when he had inspected it. When he looked underneath, sure enough the back axel was broken about 1/4 of the way from the right wheel. I am grateful we made it home safely. Three times on our way home our van was fishtailing and another vehicle was coming from the opposite direction and we nearly had an accident. Very scary! I couldn't drive over 45 mph on the pavement, or 20 mph on the snow covered, slush covered roads. The van felt like it was sliding all over from the back.

The rear axle of my 2002 Ford Windstar broke yesterday. I was traveling about 15 mph when I hear a not too loud bang and when I exited my car and saw the wheel, I knew right away what had happened. I contacted Ford this morning and I was told that it would take minimum 3-6 months to fix.

2002 Ford Windstar front sub-frame corrosion extensive corrosion to sub frame mechanic insists the automobile is not safe to drive in current condition.

2002 Ford Windstar 114,356 miles driver side rear axle has a hole rusted in bottom of the u shaped axle.

I own a 2002 Ford Windstar it was making noise in the rear so I took it to the shop and my rear axle is cracked in half my tires are leaning in I cant drive it. Its my only vehicle lots of complaints on-line you would think Ford would do something thank you.

My wife was driving our 2002 Ford Windstar regularly, commuting to basketball camps with my daughter and her friends and taking a couple one day vacations that required significant travel. She said that there was a tapping and squealing noise coming from the rear of the van frequently. She took the van out for the last time and returned saying that there was a loud bang and that the van was swaying in the rear. We noticed that the rear passenger tire was tipped into the wheel well and upon inspection found the rear axle was fractured and the two pieces were misaligned. The van is obviously undrivable and we"re in the process of determining repair costs. Unfortunately we were returning from a car dealership and were planning to return with the van to be evaluate for trade when we determined the damage.

West her Ford of amherst advised us to replace the front sub frame on our 2002 Windstar because it was cracked due to road salt. Although it passed nysi, they told us it wasn't safe to drive, so we spent $1600 to replace it (rather than replace the vehicle). Now, they've recalled the rear axle from the same model and year vehicle for the same problem (cracked due to road salt).

First time I was riding on a major highway doing about 65 mph and I heard a loud crack followed by a rubbing noise coming from the rear of the car. When I looked in the rear view mirror their was smoke coming from the back. I pulled over and my rear tires were pointed inward and the axle was broken in half. That happened around February 2010. I had it replaced from my mechanic with a used rear axle and the same thing just happened again on July 8th, 2010. After talking with my mechanic, he said his parts supply guy is getting a lot of requests for these axles.

I have a 2002 Ford Windstar minivan and I was driving down the road when I felt like I lost control of the back end of the van and then I heard metal scrapping noises. I stopped the car and found the passenger rear tire tilted in and a big crack in the rear axle. Approx speed at the time 40 mph.

2002 Ford Windstar rear axle cracked.

2002 Ford Windstar rear trailing axle broke completely ,can not be welded back together. Driving along a country road about 35 miles an hour and it just gave way. Vehicle had been inspected recently with no defect recognized. Owners need to completely replace the part with a new axle as part can not be found in salvage yard in our area due to this being a very common issue.

1. My wife was traveling east bound on rt59 in stow, OH at 36 mi/hr. There had been a knocking noise coming from what we thought was the rear driver's side tire the week prior. We had a mechanic work on the brakes and fluids and asked to investigate the sound. The mechanic was unable detect anything wrong with the vehicle. So we continued to drive the vehicle. 2. The 2002 Ford Windstar's rear axle broke in half causing my wife to lose temporary control of the vehicle. She was able to regain control and pull over, avoiding serious injury. 3. We had the entire rear axle replaced at a cost of $1200.

2002 Ford Windstar rear axle is cracked on both sides. Vehicle has 104,000 miles. Well maintained and never abused. I was shocked and in awe when I noticed this today while I was rotating the tires. I went on the internet and found this was a common problem and under investigation. I am a safety professional and a member of the american society of safety engineers (ase). My two children ride in this vehicle every day. Some of these vans are used at daycare denters and small bus companies. This is a serious defect. I have read comments about people down-playing this, and feeling this is a waste of time. This investigation is completely justified and rational. Owr van is in great shape and showing no other signs of major rust or defects. If this had failed on the highway, the results could have been deadly. These are family vehicles designed specifically for transporting a bunch of kids. I drove two 5 year olds to a birthday party 40 miles on the highway yesterday with no knowledge of the problem. Feel free to contact me. I can provide pictures. Thank you.

Backing up when rear axle broke on vehicle.

While driving our 2002 Ford Windstar at approximately 40 mph on route 22 in union, NJ, the rear axle broke in two. The vehicle started exhibiting some control problems with the rear end swaying prior to a loud bang followed by the vehicle dragging to a stop. The rear tires rubbed against the inside wheel wells producing odor and smoke at the vehicle came to a stop.

2002 Ford Windstar; the rear axle broke in two while driving at 40 mph. Both tires tilted out, axle cracked a little to the left of center while looking at it from the rear of the vehicle. Fortunately my wife was able to control the van. I understand this has happened in hundreds of Windstars, and something needs to be done before people die, if they have not already.

2002 Ford Windstar with 118,000 miles. Rear axle cracked. Had to replace axle for 1000. My family could have been killed. I have seen many complaints about this. Do something.

Yesterday, March 15, 2010, I was driving back to work after lunch and noticed an unusual rubbing and rattling sound at the rear of my 2002 Ford Windstar van. I pulled into a parking lot to look at the tires (I thought one might be defective) - I didn't notice anything unusual. I continued on to work (approximately 1/4 to 1/2 mile away and parked my vehicle. I got down and looked under the rear of the vehicle and saw that the rear axle had broken completely in half and the right rear tire was leaning into the fender well. It was obvious that I would not be able to drive the car so I called a tow truck to have the vehicle removed to a repair center. The result was that I had the part welded back together but the tires are still cocked out at an unusual angle which I am pretty sure will cause the tires to wear in an unsafe way. Not only that but the rear end of the van sits at an odd angle now. I just purchased the car in October 2009 and it only has 52k miles on it. I went online and checked to see if there have been any complaints regarding this problem and found that there have been numerous complaints about this model vehicle with the very same problem. I was surprised that were so many. I sent an inquiry to Ford motor corp and am awaiting a response in regards to repair or replacement parts support.

Went over a small pot hole and rear axle broke. Needed to replace rear axle. Axle also needed to be repaired for crack in 2009.

Our 2002 Ford Windstar se on chrstmas night on our way home from in-laws the rear axle snapped in half, after searching online I found that this happened to 2 other people and feel this is a life threatening problem and Ford should make a recall on issue. Being this happened on a holiday we have to wait till Monday morning when our mechanic opens shop to find out what we are going to do. Also our insurance company was notified and is sending someone on Tuesday to appraise the damage. . Read more...

The contact owns a 2002 Ford Windstar. During an oil change a mechanic discovered frame corrosion. The vehicle has not been driven because the engine can fall out without any prior warnings. The current and failure mileages were 80,000.

I have a 2002 Ford Windstar sel. In October of 2009 my van started pulling to the left and became hard to control on the road. When I looked at my van from the back I could see my back tires were bowed outward. I took my van to the auto shop and was told the back axle was cracked and ready to bust. I have read about this same thing happening to other consumers with 2002 Windstars and I think it's a major safety issue and a recall should be issued. I had a large repair bill and my brand new back tires were completely destroyed and had to be replaced due to the bowing of the tires as a result of the busted axle.

My 2002 Ford Windstar has a cracked rear axle! my fiance noticed it "fishtailing" alot and a noise from the rear of the van. I checked right away and saw the tire leaning in on the passenger side. Upon looking underneath I saw the axle cracked almost completely in two! searched the internet and got hundreds of hits on Windstars with the same problem!!.

Clunking noise heard in right rear of 2002 Ford Windstar. Inspection by owner found crack in rear axle beam. Ford dealer replaced axle beam stating it was cracked due to improper jacking. They pointed out two "dimples" in the underside of the axle beam as evidence of the improper jacking, and stated that the crack started there. After the rear axle beam was replaced, I investigated the underside of the new beam, and found the identical "dimples" were present on the new beam. These "dimples" are, I believe, caused by the forming of the beam by the manufacturer and not due to improper jacking. I believe that the rear axle beam of my Ford Windstar cracked because of an inherent defect caused during the forming process.