Metal Noise Problems of Ford Windstar

The rear axle of my 2001 Ford Windstar has snapped in two pieces while riding at 45 mph. The van swayed violently but I was able to bring it to a safe stop. Prior to axle snapping I heard and felt cracking metallic sound from the rear of the vehicle. I investigated this on the internet and found that have been numerous incidents involving Ford Windstars and broken rear axles. I could not imagine what would happened if my family was in this vehicle at the time the rear axle snapped in two. The extra weight in the car may have caused the vehicle to go completely out of control and cause serious injury or death to my passengers and myself. I am wondering why the 2001 Ford Windstar has not been recalled to fix this very serious defect. This is a very expensive repair and is a result of poor design and defects in manufacturing. Please don't wait for a family to be killed in one of these vans before you recalled them. This a very real problem and the consequences could be deadly.

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While cornering at 20 miles per hour, my 1999 Ford wind star gave out a loud metal cracking noise. The driver side of the rear axle assy. Had snapped exactly where everyone who has complained about the same thing on line did. This is not coincidence nor from those, rotten denying reps of Ford, telling us that this is from jacking up the car using the improper position on this axle. Go to the actual Ford service manual and you will see instructions on doing a lot of rear end work using this rear axle housing as a jacking point ( center of housing assy. ). I work from these expensive factory manuals. Ford has a defective part and refuses to admit it. Anyone with basic mentality can understand. This is about money, not safety. I would not blame any man that would lose his family due to this nonsense denial from getting a gun and shooting these !@#$%. They don't seem to give a!@#$% about their faulty parts nor families. So far I have not heard of anyone dying in a crash, but I'll bet it will happen, if it hasn't already.

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I have a 2002 Ford Windstar with 67712 miles. The car started making metallic creaking noises from the rear end whenever I made sharp right hand turns. Inspection showed that the rear axle beam had a 2 inch crack in it. I had to have my mechanic replace the rear axle. My searches on the web revealed that this is a very common defect with the Windstars.

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Rear axle nearly severed at two location both ~ 17 inches in from the driver and passenger side rear tires on September 14, 2007. ~75 -80 % of circumference of axle was cracked through wall and axle material was beginning to yield. Very similar to a NHTSA complaint # 10190132. Had 74, 440 miles at time of discovery of this significant safety issue. Car was never used for trailing or carries any heavy loads just our young family. Car has been well cared for and garaged kept. Had been hearing a faint metal grinding sound that I heard and kept inspecting under carriage. Also, had notice several months before that rear end felt spongy. Had replace rear shocks and was surprised that this still did not correct sponginess feel. Metal grinding sound was noticeable when backing out driveway with slight driveway incline. When I would apply brakes at end of driveway would hear a metal click sound. Finally with high power light inspection cracks were discovered. I have full powerpoint presentation on this issue with digital pictures if NHTSA would like this detailed information. Had brought documentation to my Ford dealer and spent two week going through their Ford rep. Before they agreed to cover the $1700 replacement of rear axle. Once again they have a know quality defect and they try not to deal with this even thou this could be a significant safety issue causing potential death. Had I not discover this and axle fracture at highways speeds I hate to think what would have happened. This needs serious attention and action to save lives . . .

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Broken rear axle, 2002 Windstar. I heard a metal to metal noise from the rear of the car while driving. It was worse while turning, or over a bumpy surface. After inspecting the car I notice that the rear axle was cracked and just about to break. I had the problem repaired. (photos available of cracked axle).

Left rear tire was leaning, noticed metal on metal sounds, then discovered the rear axle was snapped at a joint point.