Nine problems related to manifold/header/muffler/tail pipe have been reported for the 2002 Ford Windstar. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford Windstar based on all problems reported for the 2002 Windstar.
The 1st problem, had a check engine light on my 2001 Ford Windstar, c1518 "intake manifold runner control stuck open. " after reading forums, most pointed to a plastic "bushing" clip coming off leaving a control arm 2nd problem, abs chk light and brk chk light come on after driving for a few minutes, abs module and abs sensor went out.
Ongoing problem as described in TSB 04-17-4 & 03-16-1. These TSB's tell us that Ford motor company was aware of this design flaw and continued to manufacture and sell defective vehicles. The problem exist in their faulty 3. 8l engine at the intake manifold. The poor design allows oil to seep into the intake plenum and over time the oil erodes away the rubber around the isolator bolts and gaskets. When this happens the engine reads lean fuel codes on banks 1& 2 and a vacuum leak. To compensate for these lean codes , more gasoline is pumped into the plenum causing a rich exhaust mixture which is then sent out the tail pipe into the atmosphere. Ford motor company designed and built these engines and they need to be held accountable for correcting this problem. Remember, this is an ongoing widespread problem with tens of thousands of these engines fouling up the air that we breath every day.
Rack and pinion steering split, intake manifold had to be replaced, tire rod fixed, upper plenum replaced, abs and brake light comes on, leaks coolant, etc. Etc. Etc.
There are three failures on my car that have happened within the last three months. The 2002 Ford Windstar only has 57,000 miles. 1. Intake manifold gaskets leaking: gaskets are sucking air in and not sealing properly 2. Broken strut, this is the second time this has been replaced. The first time was within 10,000 miles. 3. Abs control module: the control module has been diagnosed and faulty by the dealership. About a $1,200 to replace. All these things should not be happening to a car that is maintained well, garage kept, and only has 57k miles on it.
The contact owns a 2002 Ford Windstar. While driving at an unknown speed, the vehicle hesitated. The contact took her vehicle to the dealer on numerous occasions within the past two months and they replaced the intake gasket manifold, spark plugs, and camshaft position sensors. The repair cost exceeded $4,000. None of the repairs have been sufficient in correcting the failure. The contact is currently in the process of having the vehicle repaired. The failure mileage was 115,000.
The contact owns a 2002 Ford Windstar. While idling at a stop light or stop sign, the engine began vibrating and the battery light illuminated intermittently when the vehicle was placed into park. In addition, the rpm's decreased as if the vehicle were about to stall, but then went back to normal when the vehicle was placed into park. Two weeks later, the engine light remained illuminated. The dealer stated that the intake manifold needed to be replaced. The purchase date was unknown. The current mileage was 72,914 and failure mileage was 68,000.
: the contact stated the check engine light illuminated and a growling noise was heard while driving 40 mph. The vehicle was taken to the service dealer. Computer diagnostics were performed and the code po174 came up identifying a vacuum leak. The items recommended for replacement were the intake manifold gasket and associated parts, outer tie rod end and front axle seals, transmission pan gasket and filter. The insurer sent an investigator, who verified the service recommendations. The manufacturer was not notified. Updated 12/5/2006 -.
The contact owns a 2002 Ford Windstar. While driving approximately between 35-40 mph on normal road conditions; pressure was applied to the brake pedal the front btakes locked and the driver was unable to turn the steering wheel. The vehicle also skidded without warning. The failure continued to occur intemittently. The "brake" and "abs" warning light indicators illuminated on the instrument panel. The warning indicator remained illuminated until the engine was shut off by the driver. The contact was able to drive the vehicle with caution; however, there was an increase in the engine rpms. An authorized dealer replaced the intake manifold gasket and the alternator. On a separate occasion, the the air bag system failed to deploy with a level of impact to the rear of the vehicle. There were no personal injuries. The contact had concerns of the safety risk involved. The failure mileage was 70,000 and the current mileage was 119,336. The VIN number was rejected from the system which will be updated upon receipt of the safety complaint form.
While driving check engine light came on. Vehicle was then taken to a dealership, who performed a diagnostic test that indicated that the intake manifold upper and lower gaskets needed to be replaced. The parts were replaced, but the failure recurred 13000 miles later. The vehicle was then taken to a mechanic, who also performed a diagnostic test in which the failure codes were 171 and 174 . The mechanic changed 4 02 sensors, and did a tune up. Also, mechanic a contacted dealership on this issue, who sent them a fax stating if these codes appeared it was a malfunction of the mil lamp, and didn't change the O2 sensors because this wasn't what was causing the problem. They should go to the vacuum light on the intake manifold, and if the fuel pressure on the manifold was lose due to oil contamination then the vacuum line should be replaced, and a new designed lh service cover should be installed or there could be a leak in the intake manifold. Vehicle was then taken back to the dealership, and a diagnostic test was performed again, in which the failure code indicated a leak in the intake manifold.