Three problems related to manifold/header/muffler/tail pipe have been reported for the 2003 Ford Windstar. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Ford Windstar based on all problems reported for the 2003 Windstar.
Our 2003 Windstar started misfiring badly and the engine light came on. I bought a code reader and found the codes 171 and 174 and misfire in cylinder #5. After doing some research I found this is usually due to the intake manifold gaskets leaking and is very common. I've had it with this van and I'm afraid to park it in the driveway near the kid's room in case it catches on fire. In the last few months I've replaced a broken (not rusted) front spring, brake deactivation switch, transmission (152,000km) and now this. Also the abs light is on all the time now meaning that it doesn't have anti-lock anymore. I'm a licensed autobody technician and realize that cars require routine maintenance and parts replaced from time to time and I do most of the work myself, but when they are widespread safety and reliability issues it makes me extremely frustrated that nothing can be done. I want to just park the van, but we still have a year left on the financing.
I own a 2003 Ford Windstar that was purchased in September of 2003. I had so many issues with this van since purchasing it, it's not even funny. It started out with the door locks and the back hatch door not operating correctly. . . . There were also some cosmetic items that were defective. The most annoying problem occurred in August of 2005 and has continued sporadically over the course of the last year. The van stalls out while driving down the road!!! you lose the power brakes and power steering when this happens. . It has been in the shop probably four times over the course of the last year. The first couple of times they would return the van with the explanation "no problem found". I have had people riding with me that have experienced this problem first hand. When it first started happening it was only when it rained. . And it was very sporadic. . . Then it started happening even in dry weather. I just got it back after having left it at the dealer for almost a month!!! the repair order states that the intake manifold gaskets were replaced. . . That was July 25th 2006. During another visit they replaced a cam shaft position/cylinder??? so now they tell me that because they replaced another part, that this is not considered the same problem. This van is a lemon!!!! and Ford needs to take a look at these issues. . . . And do what is right for the consumer. I. E. Refund the purchase price of these vehicles!!!.
Twice my vehicle went in for repair for engine running lean. The first time they said it was a faulty mass flow sensor, $ 400. 00 to repair. A few months latter the same code comes up I took it back to the dealer. This time they said Ford had issued a repair for the vehicle. It seems the valve cover was faulty and allowing oil to drip down and caused the gasket on the intake manifold to leak causing air to leak in the engine, which caused the engine running lean copde to come on. They have had quite a few Windstars with this problem. That is why they came out with the service bulletin to make the repair. Which included a new valve cover and other parts. Which cost another $ 700. 00 to repair. I believe that Ford should be responsible for the repair as there was a faulty valve cover that caused the engine running lean code to appear.