Problems with 2001 Ford Windstar WHEELS

Axle snapped while driving on highway rear wheels bent inward.

1. rear axle fractured severely & broke making the car un-drivable on 24 jan 2019 while in motion driving in city traffic. ford put braces on this vehicle under recall# 10s13, but they failed to prevent further corrosion and metal fatigue. the axle was a bad engineering design from the drawing board combined with not e-coating the metal during manufacturing to prevent corrosion of the metal due to road salt. the axle fractured next to the brace on the driver side as shown in the 4 images below. i have one tow bill (flat-bed) to get the car off the downtown street to my home & will have another tow bill to transport it to where i can replace the axle. 2. front cradle frame's mount rusted off that anchors the stabilizer bar so the stabilizer bar had to be removed. this happened several years ago. the cradle frame probable was not e-coated during manufacture either. i can take a pic and probable have the repair invoice detailing the date and the mechanic's work to remove the stabilizer bar. to fix the car will need a new front cradle frame, stabilizer bar, and possibly mount brackets.

Rear axle break due to corrosion of acknowledged inadequately designed axle. break happened in the reinforcement bracket installed do to initial axle recall for potential break due to corrosion.. car was on city street in motion to freeway onramp fortunately the axle broke prior to entering freeway. axle break resulted in sagging axle and a wheel tilted inward at about 20 degrees and wedged against the inner wheel well. tire started to smoke. car is undriveable. the repair is estimated to $1400. ford will not accept any financial responsibility for this break in the brackets installed to prevent the break. additional components are also needing repair and replacement due to the break of the axle.

Rear axle snapped while driving on normal roads. *tr

Tl* the contact owns a 2001 ford windstar. the contact stated that the front subframe was severely corroded and an abnormal noise was heard from the front passenger wheel. the vehicle was taken to the dealer where it was confirmed that the vehicle was severely corroded and was previously inspected per nhtsa campaign number: 11v030000 (structure). the vehicle was not repaired. the manufacturer was notified of the failure. the failure mileage was approximately 146,000.

Tl* the contact owns a 2001 ford windstar. while reversing at approximately 1 mph, there was an explosion on the rear passenger side near the rear tire. in addition, there was an abnormal noise coming from the rear passenger side after the tire was repaired. the tire had fractured. the vehicle was towed to an independent mechanic for diagnostic testing. the technician stated that the rear axle had fractured and that the vehicle needed to be towed to a dealer. the manufacturer was not notified of the failure. the approximate failure mileage was 179,000.

While driving the vehicle at highway speeds, i heard a crunching sound in the rear of the vehicle. the vehicle then began to sway on the road. i had to slow my speeds and pull over at a safe spot, which was a parking lot to inspect what the issue was. after inspection, i noted the passenger rear tire was at an angle with the top of the tire inward touching the frame. i took the vehicle to the closest repair shop where i found from their inspection that the axle was broke and the vehicle was not driveable. my vehicle was part of the ford windstar axle recall, which was serviced by the local ford dealer in 2012. this vehicle had the reinforcements added to the axle in 2012. the axle broke between the reinforced plates welded to the axle during the recall check. now after towing the vehicle back to the local ford dealer for inspection, i find out that ford will not stand behind the issue and not repair or replace the axle due to the length of time from the recall. i feel lucky that i was able to maintain control of the vehicle when the axle broke.

Tl* the contact owns a 2001 ford windstar. the contact stated that while driving at 55 mph, the right passenger side tire failed and noticed that the sub frame rotted out while installing the spare tire. the vehicle was not diagnosed or repaired. the manufacturer was notified of the failure. the failure mileage was 177,000.

The rear axle broke in the place that was "fixed" by the recall work in 2010. noticed squeaking noises (tire was rubbing) and a large clunk and wiggle when turning into a parking lot. took a photo when i got to the parking lot. my rear driver's side tire was at an angle to the vehicle and the rear axle was broken under the collar that had been attached by a dealer for the recall. the weld held up, but the axle snapped underneath the fix-up job. apparently the recall fix wasn't really a fix. towed it into a dealer, who took photos and talked to ford. ford said they wouldn't do anything. cost me $$ to tow it to the dealer and back home again. don't have $1,000 to pay the dealer for a new rear axle. very disappointed that they didn't stand by their work. very thankful that i was not on the freeway, and that all my children were not with me at the time. it could have been so much worse! *tr

We had our left rear tire blow out and it tore off our fuel filler pipe. i imagine this could be extremely dangerous if the rim had sparked it could have caught fire. *tr

During normal operation of vehicle at posted driving speed limits the vehicles abs, brake warning lights have continuously come on after driving begins. it has been also noted that after several brake service inspections and repairs at major auto repair shops, such as midas, carx , and pep boys. technicians have observed that the brake systems major components and hardware appeared to have failed due to high levels of corrosion and easily rusting parts such as brake shoes, pads, wheel cylinders, brake drums, brake line hoses and connectors. each of these repair shops have informed me that the repair/ replacement of many of these vital components would be extremely costly to repair and could result in serious injuries or create a hazardous situation for the vehicle's operator and other drivers if not repaired immediately. the vehicles brakes and hardware have been replaced more than three times by asae certified /qualified mechanics and the brake systems warning lights continuously remain on during regular operation. the rear brakes are grinding and wearing the brake shoes down much faster than they did before even after repairs have been completed. currently when applying the brakes before coming to a full stop the brake peddle must be applied at a distance of at least 30 seconds sooner to ensure a safe stop. i do believe that there is a high risk of concern in the failure of the ford windstar brake system operations and a thorough inspection of the abs system and brakes including its major components should be inspected immediately to prevent a serious accident or injuries to the vehicle's operator and to protect the safety of the general public. *js

Vehicle had voluntary recall done to it in 2011. it has now broken in same place as others have explained. recall is a sham and ford is getting away with continuing to replace with defective parts. please investigate. *tr

We left the house and was driving and the van felt like it was sliding back and forth. i stopped and checked and the back wheel was setting crooked. i checked the lugs and the were tight. we turned around went back home. i looked under it and found the axle cracked and broke. we called ford and they had a recall on that but said they were no longer repairing them. *tr

On 01/06/2011 i took my minivan in for the recall on the axle. they told me it was fine and sent me home. on friday while driving on northline road in southgate michigan, my axle snapped. i took it to the taylor ford and they said it would be fixed by ford. i was told today 05/28/2013that they would not cover the repair due to the fact they put brackets on it in 2011. i was not informed of the fact they put brackets on it in 2011. i was driving a vehicle that was dangerous on the freeway. *tr

Rear axel broke. *tr

occurrence: 12 october 2010. traveling i-95 washington,dc/suitland, md. vehicle: ford windstar, 2001. speed : 60-65 mph. traffic : dense. failure of defective part : rear axle snapped in two parts while traveling on smooth highway, northbound. explosive sound , lots of smoke, extreme consternation/fear of heart attack experienced by my wife and i ( my wife has a dangerous heart condition "ihss") at occurrence. i immediately turned on hazard flashers. managed to maneuver across several lanes of traffic to get to highway shoulder safely!! thank god for the alert fellow travelers behind us!!! if we were hit by any 18-wheelers on the highway, i wouldn't be writing this complaint now!!! concern for our safety was shown to us by fellow travelers; particularly, md traffic safety person, who should be commended by his superiors for his professional and understanding actions!! he looked at the damage and said that he had never seen anything like it before; and he said that we were lucky to be alive!!! van was transported by professionals to the nearest ford dealership where i first became aware that a recall notice was in force for my vehicle!!! at this point, i became greatly disturbed that i had no previous notification of this dangerous condition and that my wife, grand children, etal were traveling in potential rolling coffin! in my opinion, this seems to be criminal; particularly if greater profit motives might be involved! i certainly hope that inferior materials were not used in this regard!! i was informed that my van would have to remain at the ford dealership until ford motor company decides how i will be provided with a safe vehicle , since no replacement axles were available. (nb ; i have no idea whatever other damage exists as a result of this awful failure! i certainly don't want a duplicate axle replacement to replay this horrific catastrophe! in my wife's delicate condition, i cannot expect her to travel in this unsafe vehicle! justice!!! *tr

Rear axle snapped on 2001 ford windstar lx van while driving at highway speed. *tr

Normal driving of 2001 ford windstar. rear axle broke and car was non drive able. rear axle design is obviously bad and can create a life threatening condition as the rear wheel assemblies would fall off. at highway conditions this would be catastrophic and would be life threatening. very poor design that does not allow road conditions for a factory auto with 8 seats. very bad estimates of passenger weight and safety factors. vehicle never in a hard crash or hard damage. never used to carry heavy equipment or non ordinary family travel. design of back wheel assembly is a formed metal and not a solid structure to meet normal highway conditions. metal sheared most of the way through. obvious design limitations that will not meet multiple passenger operations on local roads and highways. very-very dangerous design and fabrication specifications. axle was welded to make it slow road worthy to get it to car repair shops. replacement of bad axle is necessary for complete operation. calls to ford dealers resulted in conversations that ford would not fix obvious flaws at their expense. life threatening design, engineering, and fabrication must be corrected by ford. critical failure would cause major problems. car shops claim that material and design caused problem as no damage or collision was made. *tr

Tl*the contact owns a 2001 ford windstar. the contact noticed that the top of the wheel was leaning inward and the bottom was leaning outward. he also noticed that the linkage between the two wheels was cracked. the contact drove the vehicle to his residence. the dealer and manufacturer have not been notified. the vehicle has not been repaired. the vin was unknown. the current mileage was 75,500 and failure mileage was 75,000.

Government has never answered odo 10252007 (life threatening ford 2001 windstar axle defect. *tr

Vehicle shook uncontrollably while making a right turn. driver applied the brakes and the pedal went to the floor. driver was able to maintain control of the vehicle. the left front wheel sheared off, and the lugs: nuts were still attached to the wheel. vehicle was towed to the dealer, and mechanic determined that the wheel, lugs: nuts, and other parts needed to be replaced. *ak

The rim on the vehicle separated.*jb

The rim cracked into the tire, which caused the tire to leak air. *jb

Interior lights flash on and off including dash lights taken in on numerous occasions but problem still exists to this day. abs and brake lights come on constantly up to and including today. noise that sounds like bones crunching from steering wheel or under foot? and buzzing from right front tire on left turns. took into ford dealer for all complaints, never fixed. *tr

At 20-25mph front right wheel bolts and nuts separated, causing damage to vehicle. dealer is inspecting vehicle.*ak

No summmary listed for above vehicle. *ak