Frame Rust Problems of Ford Windstar - part 2

Tl-the contact owns a 2001 Ford Windstar. The contact stated that while driving at various speeds and going over bumps and pot holes she would hear a loud grinding noise. The vehicle was inspected by a independent mechanic and they advised her that the cradle to the frame was severely rusted. He advised her to not drive the vehicle because it may detach while driving. The vehicle has not been repaired. The failure mileage was approximately 110,000. The VIN was unavailable. Tb.

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I have 1999 Ford Windstar 3. 8 liter with 123297 miles, I own this car since 2000. The passenger side rear subfame end at the mount is roded out,split and came off the bushing. I had taken it to sears on 01/21/11 and had advised that it is unsafe to drive the vehicle. I had contacted Ford dealer and explained that there was a recall on the rear axle for rusting. This is similar situation and should do reparis at no cost to the owner. The dealer gave me Ford toll free number. When contacted Ford they advised that they are not responsible for the repairs as the warranty is over. I explained it is a bad product and failure due to rusting is similar situation as an axle rusting. If an axle rusting is honored by Ford why not frame rusting. They said I will be responsible for the expences as there is no warranty. I went to well known body shop macco they advised that the frame will cost 1000 plus 950 labor to put the accessories back. I can not efford to spend this kind of expense. I had already put 2500 in transmission after I purchase the vehicle. The rear electronic module has failed which will cost 800 dollars. I have to keep pouring money in this car. Any help is appreciated.

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Rusted subframe.

My front subframe is rusted on my 2000 Ford Windstar and could not be repaired had to replace subframe. When I purchased put Ford reman transmission in veh and now Ford will not fix wants to buy me out for $2,900 my veh only has 95,000 miles and where would I get a veh like this for $2,900 do not think is fair they should replace the front subframe.

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Right passenger subframe rusted and rear engine mount separated from frame due to rust--no longer able to bolt new mount to the frame as the frame is corroded and a crack is present.

Sub frame rusted.

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While driving my 1999 Ford Windstar I started to hear a grinding scrapping noise when making right turns the noise progressively started to get even worse I started to hear a loud clunking noise brought car to mechanic inspected and found that the sub frame was completed rusted out and the engine could drop at any time was advised not to drive vehicle ,luckily nothing happened when I was on the highway with my daughter driving at highway speeds. I contacted Ford and they have told me there are no recalls on this particular situation, after checking online I have seen so many complaints I am now out a car and no money to buy new one, thank god my daughter was not hurt or anyone else I wish Ford would realize this very dangerous situation and not wait for someone to get killed!!!.

On December 27th, my wife had her Ford Windstar lx recall on the rear axle fixed at jim kiem Ford in hilliard, ohio. She also wanted Ford to look into a really bad noise that she was hearing in front when she was turning. It was a loud banging noise. Jim kiem Ford told us that the sound that we heard was the sub-frame. They said the sub-frame was rusted and that the vehicle was unsafe to drive. They said that the engine might fall out of the car! my wife and children have been using this van everyday. I have read many Windstar owners comments online about the same problem. What does it take to get a recall? do children have to die!.

1999 Ford Windstar lx front sub-frame rusted out on passenger side. This section of the sub-frame is always wet when the air-conditioner is turned on in the summer and the condensation from the air-conditioner leaks onto the subframe at this specific area, and in the winter salt is causing sub-frame to rust out and break at this specific area. This is a design flaw.

I have a 99 Ford Windstar with sub-frame rust. The vehicle was taken to a local Ford dealer and put up on a lift and inspected after I noticed a noise and pulling to the right. The sub-frame has completely rusted away on the passengers side where it mounts to the vehicle. The vehicle itself has little to no rust underneath except to the subframe in two spots. The vehicle cannot be driven now and I was told the subframe would have to be replaced. Due to the vehicle not being rusted underneath and not being driven in salted road conditions, I would have to conclude this is a manufacturer defect? the Windstar is clean enough underneath to almost eat off. Again there is little to no rust underneath except to the subframe. Thank you for looking into this matter.

Took my 1999 Ford Windstar to have front tires replaced and mechanic noticed the front passenger side subframe mounting bolt is severely rusted. When I took the vehicle in to the dealership to have the recall work done for the rear axle, I told them about the rusting of the subframe mounting bolt and they said I would have to make another appointment and pay for this myself because there is no recall for this problem. My vehicle is not safe, I am scared to drive it, and I don't have the money to fix it!!!.

The contact owns a 2001 Ford Windstar. The contact stated that the passenger side subframe had rusted; the vehicle made a thumping sound as if the wheel would fall off. The contact also noticed that the bolts near the wheel were also rusted. The vehicle had not been inspected or repaired. The VIN was unavailable. The current and failure mileages were approximately 120,000.

Our 1999 Ford Windstar was found to have serious rust on sub frame on passenger side during a massachusetts state vehicle inspection today. I understand this make and model is subject to a recall investigation and I want my complaint added to that investigation and request a recall notice be issued for this vehicle.

Mounting bracket for the lower control arm on the subframe rusted and broke, making tire change direction while my wife was pulling into the driveway. The axle slid out. Subframe has to be replaced. Dealership quoted about $1500 to repair. Rear axle is involve in recall. I believe this should also be recalled at is a safety concern that should not happen to a vehicle only 8 years old.

Front sub frame rusted out on the right passenger side. After going to a transmission shop to have my trans rebuilt I went to a mechanic to see why I kept hearing strange noise from the passenger side of the van. When the mechanic lifted the van he showed me the rusted subframe and stated that eventually it will fail and that it needs to be replaced. The only way to resolve this problem is to replace the sub frame, because it is too thin to weld in their opinion.

2000 Ford Windstar lx 95,000 miles. Rear axle is cracked. Right rear subframe is completely rusted through where it mounts to the frame. Both parts are ready to fail and could have resulted in injury or death. Please recall the Windstar for the rusted subframes before people start getting hurt. It is a real problem and you will receive many more complaints. That nonsense Ford is spouting about rust is normal on vehicles of this age is not going to fly. Body rust is normal in the "salt belt", frames and axles rusting to the point of breaking is not. I bought a Windstar for it's five star crash rating. I thought it would keep my family safe!.

My Windstar is at dealers for broken rear axle and I was told front subframe is rusted.

Around October 20th, 2010, my 1999 Ford Windstar was making a weird noise when I a make a right turn and also when I step on the gas pedal. The noise came from the front right of the vehicle, at first I thought it was a brake problem. I took it right a way to my mechanic to be diagnosed. When the technician lifted the van, he noticed right a way the sub frame all rusted and broken. My mechanic did not let me drive it because it's a high risk, he said the engine can fall any moment. Due to the high cost of replacing a new sub frame, the technician suggested a used one but in good condition. It cost me $723. 00 to replace it. I went to the nearest Ford dealer to complaint but I was told that specific part of the vehicle was not recalled and it's due to the age of the vehicle. I am still afraid to drive my Ford Windstar even after I replaced it. Currently my van is sitting at Ford dealer parking lot, it's under recall for the rear axle.

After receiving information about a recall for the rear axle on my 1999 Ford Windstar I decided to take a look at it. After looking under the entire vehicle I found that the front subframe is rusted through also, and is unsafe to drive as it will break off at any point in time. I think that Ford obviously has corrosion issues with these vehicles, and something should be done about it. I will be towing my van to the dealer to have the rear axle inspected today. I hope something is done about the front subframe, because this could really hurt someone.

I had my car in to a Ford dealer in massachusetts for the recall of the rear axle. When they were done checking the rear the mechanic told us not to drive vehicle due to failure of the sub frame on the right front. The frame had rusted and broke around the bolt. Luckily it didn't break while traveling on highway.

1999 Ford Windstar right passenger front sub frame rusted thru and broke apart causing steering wheel to be thrown off center and directional not to work. It was found when al of a sudden we herd an exhaust noise and looked under the front of vehicle. It has separated at least 1" 1/2 and we were told by a Ford master mech who looked at the van said it can not be driven as it could cause an accident with possible injuries or death.

The contact owns a 1999 Ford Windstar. While having the vehicle inspected at the local dealer, the contact was informed that the lower frame had rusted. The vehicle had not been repaired. The current and failure mileages were 113,345.

Clunking noise from r/f of vehicle when turning left, and severe pull when accelerating. Found front subframe rusted thru and cracked at passenger side rear mount. Had to replace front subframe.

Front sub-frame or engine cradle 1999 Ford Windstar. Noticed loud scraping noise when turning to the right. Vehicle inspected and found one of the front sub-frame mounts rusted through and almost separated from round rubber. (right side, back) all other 3 mounts are fine. I was told "do not drive" told me I was lucky I didn't lose my whole engine. They also said it could be due to the a/c drain tube located above this mount. Strange all other mounts were fine.

Went for a routine oil change and my mechanic discovered the passenger side sub frame is all but rusted out.

Our 2001 Ford Windstar started making a popping noise a couple of months ago, usually at slow speeds and while turning. When we had it checked out, we were told the subframe has rusted through at one place. This could potentially pose a significant safety risk, as the motor mounts, steering control arms, etc. , are attached to this subframe.

Noticed loud scraping noise when steering had vehicle inspected and found right front sub-frame rusted and separated from round rubber bushing looking into repairs now and found online that it is a common problem that can cause steering loss.

Ford Windstar 1999: my mechanic said the front sub-frame is rusted to the point that it is unsafe to drive. I am taking it to my local Ford dealer for evaluation. Ford will also perform the rear axle recall.

1999 Ford Windstar front passenger-side subframe rusted through and separated rendering the vehicle undrivable. The vehicle can not controllably steer or brake with this condition. Luckily it didn't separate while at highway speed or it would have had a catastrophic ending. An immediate recall should be put out on this before anyone is killed.

Subframe is rusting out on 2002 Ford Windstar leading to danger.

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Vehicle became un safe to drive and swerved from lane to lane when accelerating. Found front subframe rusted thru and broken on passengers side rear corner. Needs new subframe in front.

I have a 2001 Ford Windstar which is showing signs of a sub-frame corrosion failure similar to the one described in investigation pr 10-026. There is a "u-shaped" subframe element which connects to the main frame near the outboard side of both front seats and extends forward around the front of the car. It does appear various suspension and steering members are connected to this sub-frame. The passenger-side end of this sub-frame where it connects to the vehicle frame shows severe rusting and metal delamination and a crack has formed on the end. The driver-side end of this subframe shows normal wear and is not in immediate risk of failure. The corrosion to the passenger-side end is excessive as compared to the driver's side and other frame elements in the vicinity. Something is accelerating the corrosion on the right side. It may be due to the condensate drain from the air-conditioning system. At this time, the sub-frame has not failed but the vehicle represents a significant safety risk since failure-related crashes have been reported. The repair costs are estimated to be in excess of $2000 for frame replacement. I believe that Ford should quickly develop and deploy a means of reinforcing the frame member and offer the repair via recall to Windstar owners. Since the parts are currently still on my vehicle, I can take photographs showing the deterioration of the sub-frame ends. As a side note: my Windstar is equipped with the rearseat air-conditioning system. The evaporator is in the rear quarter-panel on the driver's side in the rear or the vehicle. While this affected components do not appear to be a critical part of the vehicle's structure, there is significant corrosion to the parts which are in the path of the condensate drain for the rear a/c system as well. This seems to confirm the belief that a/c condensate run-off is a key factor in the sub-frame corrosion issue.

Subframe severely rusted @ rear engine cushions. Must be replaced immediately.

I was servicing the brakes and notice the right side of the sub-frame (engine cradle) was rusting away. I was telling my father about the frame rusting and he had thought there was a recall on that. I started searching the internet and found alot of people with the same problem. But no recall info. I am not sure if the van is safe to drive. I also own a 2000 Windstar and it showing the same signs of heavy rust in the same area.

Noise heard in front end. Suspected problem possibly with joints. . . . Turns out to be a rusted and cracked frame. This is the second time within the last two weeks the salvage CO who took our car witnessed this same problem. Dangerous!.