Problems with 1999 Ford Windstar STRUCTURE

Took my van into midas for an oil change, the mechanic called me out and showed me the k frame is rotted and hanging off the vehicle on passenger side of vehicle. this is also caused additional front end damage. mechanic told us do not drive this vehicle. it has been sitting in the front of our house since. *tr

I have a 1999 ford windstar, which has badly rusted k cradle, which can cause the engine to fall down while being driven as told by the mechanic. i tried to find an used one but couldn't get as they were all rusted out. looks like it has bad material or bad design. its a real safety hazard. *tr

Tl*the contact owns a 1999 ford windstar. while driving 35 mph there was a loud noise in the rear of the vehicle. the vehicle was taken to a local mechanic who stated that the rear end was covered with rust and replaced it for $700. the manufacturer was not notified. the failure and current mileages were 187,000.

While driving thru an intersection, there was a loud clunking noise. the steering wheel turned hard itself, and the van was undrivable. the mechanic told us that the engine cradle was rusted thru an had broke off from its mounting point. he said this was a design flaw from ford, and that he has seen several windstars with the same problem. there are no recalls yet, and ford will not help, yet. after searching the internet i was surprised at how many other people have had the same problem. coincidently all the other windstar mounts broke in the same exact place. the mechanic has quoted us $750.00 to replace with a used part and $1300.00 for a new part. so far all of the used parts are rotted (rusted thru), in the same place as mine and not worth using. if we cannot find a quality used part soon, we will have to replace with new. *tr

Rusted out sub frame. it cost me $1,150.00 dollars to repair with a used one. not happy. tranny slams from 1st to 2nd gear; it started about 6 months after i bought it in 2001, they fixed it. then it started again in 2006 when it hit about 80,000 miles. i stopped driving it for awhile after fighting over it with the miller ford dealer then finally got the money to repair the sub frame. now i just drive it and use 2nd and 3rd gear. the od light keeps coming on. *tr

Chassis rusted out around mtr mounts: car makes noise and steers crooked: i just found out why but, it's been doing it for about 6 months. *tr

The sub frame on our 1999 ford windstar broke at the right lower control arm. the break occurred just as my wife had left the highway and was fortunately traveling only about 20mph in a straight line. the vehicle would not steer and it could not be removed from the road, as the half shaft had pulled out of the transaxle. my wife left the vehicle with my two children to get assistance, and by the time the towing service that we called had arrived, the local police had the vehicle removed from the road due to its location. we then had it towed from the police impound to our garage. an estimate of $1200 was given by our shop but i felt that it was too much to spend on this repair. we towed the vehicle home and i replaced the k-frame myself, and had it aligned by our ford dealer. it was interesting to see that many of the frames in the salvage yard had a similar rusted condition in the same location. the frame i located had been replaced within the last year, still had fresh paint and part numbers on it. it was very fortunate that this failure occurred in a straight-line, decelerating scenario at slow speed and no one was hurt. it would not have been the case at higher speeds or with turns. it is also relevant to note that the vehicle had recently passed its annual safety inspection, at a ford dealership, and this frame weakness was not detected. *tr

1. sub-frame was badly rusted out. it broke while backing out of a parking space and the front tires disengaged. 2. the rocker panel on the left side needs to be replaced. it is badly rusted out and it will not pass inspection anymore. there is some rust on the right rocker panel also. all of the rust in under the vehicle and it is not safe to drive. 3. the check engine light came on last year.

Tl*the contact owns a 1999 ford windstar. the vehicle was being state inspected when the mechanic informed the contact that the subframe was severely rusted and should not be driven. the vehicle was taken to an authorized dealer for recall 10v385000 (suspension: rear: axle: non-powered axle assembly). the contact had not received a recall notice regarding the problem. the failure mileage was 125,109.

Tl*the contact owns a 1999 ford windstar. while driving approximately 30 mph the contact stated that the vehicle began to feel unstable. the vehicle was taken to an independent mechanic where the contact was told that the subframe was severely corroded. the vehicle was not repaired. the failure mileage was 160,000 and the current mileage was 170,000.

The subframe on my 1999 ford windstar rusted out and had to be replaced in 20 09. whenever we made lefthand turns we would hear a grinding noise. i first brought the car in to be serviced in 2004. the service tech couldn't find anything wrong. i brought the car in to the dealer 3 more times between 2004 and 2009, each time a different diagnosis was made with resulting expense. the subframe was finally determined to be the problem. as i indicated it was replaced on1/2/2009 at a cost of $1014.75. *tr

After a couple of inspections and lots of clunking noises and alignment issues, my mechanic (and a mechanic from another shop) suggested strongly that i replace the vehicle's subframe/engine cradle. the frame was rusting/rotting from the inside out at both front ends near and around the motor mounts and the subframe bolts (attaching to the unibody frame). there was also some rot occurring below the area that a/c water condensation drips. the frame was replaced soon after ... avoiding driving the vehicle until repair was made. unfortunately, the old part was tossed before i could ask the mechanic to save it for me. *tr

Recent news reports have lead me to believe that i am not alone with the following problem: the rear axel of my 1999 ford windstar broke in half while i was driving onto i-93, north of boston, on december 5, 2009. fortunately the vehicle skidded to a stop on the on ramp just before merging with fast moving traffic. the windstar was towed to a garage, then donated to charity on december 7, 2009. two people were in the van, however, there were no injuries as a result of the structural failure. *tr

The lancaster ford dealer performed a recall on the rear axle subframe rust issue in a satisfactory manner. however the left side rocker panel was rusted but they didn't replace it. now it is completely gone. i am writing to see if ford replaced the rocker panels also. *tr

1999 ford windstar front subframe rotted out, cracked, and had to be replaced. *tr

The car started pulling really hard to the right while driving causing a loss of control and almost an accident. the frame of the vehicle rusted in one spot on the subframe where it joins the frame around the mounting bolt. this is on the front passenger side of the vehicle. this has broken loose and there is subframe/control arm and other damage. dealer said when a job like this is done there is usually a snowball affect with the damage. atleast $2000. the rest of the vehicle is in good condition with a new transmission just pu in last year. car is only good for scrap now. definite safety issue. i have two kids ages 3 and 5 that were in the vehicle at the time.*tr

Front frame (shop called it a k-member or engine cradle) was rusted thru & broke off where it attached to the body of the vehicle. this happened while my daughter was driving locally, luckily not on the freeway. steering wheel went out of alignment a full 90 to 120 degrees while she was driving. most shops would not fix it, but found a shop who put in a salvage yard part. ford dealer was ludicrously high dollar & very unsympathetic. *tr

The rear axle (or rear support beam)broke in two on my 1999 ford windstar. we had heard some noise from the back of the car and had an appointment to have it checked the day after this incident occurred. i had thought that maybe the rear shocks were going. i was driving the car on sunrise highway in rockville center,new york when the car started bucking and there was a loud bang. immediately the car started swerving to the right and i started t smell a burning odor. it was quite a terrifying experience and i thank god that neither i or anyone else was hurt. i was able to get the car to the side of the road as i noticed the look of horror on the faces of the few bystanders on the sidewalk. i could not believe what i saw when i got out. the rear wheels were both spread eagle apart and the axle was broke in two and scraping on the ground. there was a distinct scrape mark in the road from the axle that traced my path to the side of the road. as i searched the internet i was disturbed to see that this is an ongoing problem and that ford has done nothing to take responsibility for it. i just got my car back today, august 4,2009. i had to pay $870.00 for the repair and that is with a used rear axle support from a junk yard. this is a real safety issue and before someone is killed ford should step up to the plate and recall these cars!!! to make things just a little worse, it just happened to be my 50th birthday on the day of the incident. what a birthday present from the ford motor company. i had purchased this car new in 1999 and am the only owner. the car has not been in any accident. this is not the first major problem with this car and ford sold me an extended service contract at a significant discount after i had the car for two years because of all the problems i had with the car from day one. the car has 97,000 miles on it and has had the transmission rebuilt,new intake manifold,master cylinder,brake booster,struts,rack and pinion,and more. *tr

My sisters 1999 windstar had a rusted subframe. i took my 1999 windstar to a mechanic , the subframe was starting to rust on the right side. within 4 weeks , the frame split while driving with my 2 kids in the car. it is undrivable. i call ford on 7/22/09 to let them know of a design problem (the a/c draintube drains on the subframe on the right. there is no other rust on the car, but ford said my car was out of warranty and there is nothing they can do. its not a warranty issue, its a design issue. i am having it fixed and i think ford should reimburse me . they will need to replace the subframe. *tr

Rear axle broke on my 1999 ford windstar without warning. thought i was hydroplaning, as it was raining. at 60 mph, i started to loose control and i slowed down to 40mph. i drove 5 miles, thinking i was getting a flat tire. as i pulled off the road, rear tires were scraping the fender and i discovered the axle had broken in half. *tr

The subframe on my 1999 ford windstar is severely corroded at most of the connection points. whenever we make a turn we could hear the rattling/grinding sound coming from beneath the vehicle. this problem has not been corrected at this point, but i am considering doing some reinforcements and hoping there will a recall very soon. *tr

Tl*the contact owns a 1999 ford windstar. when the contact took the vehicle in for service, the mechanic noticed rust in the subframe coming from the air conditioning. condensation from the air conditioning on the passenger side was dripping onto the subframe, which caused the rust. the dealer stated that there were no failures and the contact would have to pay for the repair. the manufacturer also stated that the contact would be liable. the vehicle will be repaired at the contact's expense for a little more than $3,000. the failure mileage was 107,547 and current mileage was 107,560.

1999 ford windstar - subframe rusted out. had repairs done. had vehicle inspected by ford for current rear axle recall, was told there was no rust in the rear axle. i am having the car inspected by my mechanic because it would seem that if the front end rusted out, so would the back. *tr

When having the ball joints replaced and an alignment done, our mechanic noted that the engine cradle is severely rusted and needs to be replaced. he claimed that it was far worse than it ever should be and if this was a gm, they would take care of it. however, this is a ford and they will do nothing. *tr

On may 22 my 1999 ford windstar van started to make a squealing/whining noise at approximately 10:30 in the morning during what should have been a 40 minute drive to my mothers house. due to the weird noise i stopped and checked the air pressure in my tire (right rear) where the sound seemed to be originating from. the pressure was a little low so i topped it off and continued on my trip. the sound continued and i decided to stop at a service station about 20 more miles into the trip. the service station was little help, they checked my power steering fluid, drove the van around the parking lot a couple of times and it made no noises. the attendant told me he didn't have any idea as to what the sound might be and asked if i could return in an hour when his superior would be there. i agreed to return after dropping off my kids at my mothers. after going on down the road about another ten miles i felt the steering wheel start to float and drift and my brakes became useless and the van came to an abrupt halt and there was a huge bang as the entire rear end of the vehicle became disabled. as we all piled out to see what was wrong we found the rear wheels pointing inward under the van at a backwards angle. some men came to help me who were nearby they informed me my axle was snapped. looking under the vehicle i could clearly see they were right. my van will be repaired this weekend. i called ford they basically told me to eat the repairs myself. in wv a yearly inspection is required, i passed inspection at the beginning of april which tells me there was nothing visually wrong with my axle less than two months ago. i find it hard to believe that without any outside damage or force (accidents, force ect) an axle can just snap in two. if i had been traveling any faster my 4 children and myself would have been killed or harmed as at the moment it broke i had little control over the vehicle and the brakes were failing. only people with children buy mini-vans, this is scary. *tr

1999 ford windstar- was hearing a lot of deep sounding squeaking from the passenger front side. also some cracking sounds when accelerating from a stop. had a mechanic look and found the subframe was very badly rusted. we replaced the subframe. the repair shop took pictures for us and we were horrified to see how severe the situation actually was. it was very close to rusting completely through. 1999 windstar with 98,000 miles. cost to repair was aprox. $1500. the car rides very smooth now that it has been repaired. big difference in the feel. was not aware how bouncy the car was riding. now it feels almost like a new suspension. *tr

The engine cradle has rusted out on my 1999 windstar van. this has occurred due to a faulty design by ford. after research i found that the air conditioner leaks on the cradle creating a common problem of the cradle rusting out. this can be and has been resulting in car accident deaths. i was lucky. i had the car at the ford dealership in englewood florida(bay harbor ford) for another problem and they went to put my car on the lift and the cradle broke because of the rust. they are replacing the cradle and then continuing on the repairs. the cost to me is expected around $2,200 or more. they have ordered a used cradle. ford inspected my car before i purchase it and never told me about this rust problem. i purchased the van in 2007- oct based on their blessing that it was a sound, safe vehicle and would last me for at least anther 200,000 miles. *tr

We have a 99 windstar with a broken engine cradle. my wife was driving the van along with my son to a local retailer. she was in the middle lane when she heard a loud bang under the van. my son who was sitting ton the passenger side said he felt it under his feet. she was able to get the van to the side of the road even though the steering was very difficult. she was about 5 miles from home so decided to take it back home. surprisingly she was able to get it home. i crawled under the unit and immediately saw that the engine cradle had snapped on the passenger side rear. it was then that we stopped driving the van due to safety concerns. i did some research on the web and they were several complaints identical to ours. it seems that the ac drain hose is situated over the exact location of the break. apparently over a period of time this causes the frame to rust out. i called ford to complain and they said that there was nothing they could do. i called my local ford dealer and passed on buying a new part due to the cost. i had to take a day off from work and go junkyard shopping to find a replacement part. i located one and we had the unit towed to lucas ford in burlington, n.j. where my wife works part time. the part was delivered and the dealer did the replacement along with a bad rack and pinion unit that was discovered at the same time. the unit had 77,817 on the odometer at the time the work was done. i can understand mechanical items going bad but this was a structural item. this situation could have been so much worse say had she been on the interstate doing 65 mph instead of on a local road doing 40 mph. i could see if this was an isolated incident but it isn't. i contacted ford one more time and complained again to no avail. i have always owned fords and probably always will but this experience along with one i had concerning my 1985 thunderbird control module has left a bad taste in my mouth as to how they take care of their customers. *tr

Tl*the contact owns a 1999 ford windstar. the contact stated while having the inspected by the state, the inspector noticed the subframe was broken in two places. the contact took the vehicle to a mechanic to have the sub frame replaced. the contact called the manufacturer regarding the sub frame and at the time the manufacturer stated there is nothing they can do since there was no recall. the contact was unaware of the recent structure: frame and members: underbody shields (11v030000) recall and stated the manufacturer should have released this recall long ago. the vin was unavailable. the failure mileage was 38,000.

The front subframe rusted through on back passenger side. the rest of the vehicle is rust free for the most part. the car has 80,300 mi . its a 1999 ford windstar. *tr

1999 ford windstar se failed pennsylvania state inspection,due to rotting metal on front subframe,located near were connection to uni-body exist. subframe has rotted a hole and is continuing to deteriorate. passenger side. *tr

While driving in a residential area, steering wheel jerked to the right and transmission seemed to enter neutral. upon inspection, found that the weld that anchors the control arm to the engine cradle/subframe had broken. control arm pulled away from the cradle and dislodged the right halfshaft leaving vehicle immobile. vehicle has not yet been repaired. a non-moving, frictionless part should not break under normal use. *tr

While driving my 1999 ford windstar, i heard a thump coming from the passenger side front end. i then felt the steering wheel go from the 12 o'clock position to the 3 o'clock position. i stopped the minivan and got out to inspect the under carriage. i found that the subframe on the right passenger side rusted through a few inches from where it bolts to the vehicle. the vehicle s no longer safe and is currently at the repair shop being inspected. i was told by the technician that he has never seen a subframe rust through as it did. the vehicle has one owner and is well maintained. pictures available at request. *tr

Tl*the contact owns a 1999 ford windstar. while driving 30 mph, the subframe suddenly failed, which caused the axle to pull out of the transmission. the vehicle was taken to a local mechanic and they stated that the subframe needed to be replaced. the contact did not notice any differences beforehand. the current and failure mileages were 104,000.

Tl*the contact owns a 1999 ford windstar. while driving approximately 45 mph, the vehicle began pulling to the right. the contact heard a noise and the steering wheel was not centered. there were no warning indicators illuminated on the instrument panel. the vehicle was taken to an independent mechanic, who stated that the failure was related to the main engine cradle assembly. the vehicle was repaired. the contact was concerned of the safety risk involved. the failure mileage was 125,000 and current mileage was 129,000. updated 11/17/08 *cn updated 11/21/08. *jb

The front sub frame dropped down due to rust at the rear attaching points. this caused a loss of steering. the vehicle is a 1999 ford windstar van. i called ford motor company & they said there was nothing they could do, that there is no warranty or recalls for this problem. it seems that this is a serious safety issue. although there was no accident or injuries, it could very well have caused a serious accident. *tr

Tl*the contact owns a 1999 ford windstar. while traveling 30 mph the contact heard a loud banging noise in the front end of the vehicle. the vehicle was taken to a local mechanic where the front sub frame assembly was replaced due to rust damage. there were no prior warnings. the failure mileage was 126000 and the current mileage was 140000. updated 12/30/10. *lj updated 04/06/11

Tl*the contact owns a 1999 ford windstar. while driving approximately 50 mph, the rear frame spontaneously failed, nearly causing the contact to lose control of the vehicle. as a consequence, the tie rods failed and the tires are now facing inward. the contact inspected the vehicle and noticed that the rear frame was excessively rusted. the manufacturer acknowledged that there was a failure with excessive rusting of the rear frame. however, because there was no recall, they would not assume responsibility for repairing the vehicle. the vehicle has not been repaired. the contact has pictures of the failed component. the failure and current mileages were 140,000.

Started hearing a funny noise (rubbing or squeaking) on the passenger side of vehicle (1999 ford windstar). mechanic showed me where the sub-frame has rusted and spit apart. the front end of the car is literally separating from the back end. he said he has never seen this happen and recommended that i call ford. ford was no help at all. said "sorry", but there was nothing they could do. made no effort whatsoever to fix this safety issue. there was no accident with this, but there definitely would have been if i continued driving this. *tr

Hi i just saw that you were investigating windstar rust issues. two years ago, in 2008, our 1999 windstar starting making weird noises when i went over curbs or turned the wheel. i took it into the dealer and they said the front frame and axle had rusted. it was a couple thousand dollars to fix. they said it was no longer under warranty. i did not wish to fix it (since it would cost as much to fix as the van was worth) and they said it was unsafe to drive and did not recommend i leave without fixing it. so we traded it in (explaining fully what was wrong with it) when we purchased a van from the honda dealership down the road. i just saw that you were investigating rust issues associated with windstars and thought i would pass this info along. thanks *tr

1999 ford windstar van both ends of the engine cradle rotted away causing it failed inspection and calling for the entire assy. to be replaced. the estimate for the part and labor almost $1,000.00. this part is a very major part of the vehicles under structure and should never rot like this. when and if one or the other, or both should break off the entire weight of the engine will cause it to drop onto the pavement possibly causing a crash. *tr

Engine cradle rusted and broke apart. *tr

I was recently driving with my son in a 1999 windstar when the lower control arm housing broke away from the frame. the car was completely uncontrollable and we went all over the road. if anyone had been coming the other way we would have had a serious accident. every mechanic who has looked at the broken housing said that they had never seen this happen before, even on much older vehicles, and that it shouldn't have happened. most of the mechanics i have spoken to feel that a faulty weld caused this structure failure, and that it cannot be repaired without installing an entire new sub-frame. the ford dealer who sold me the van, and the ford customer service center at the ford headquarters, said that considering the age of the vehicle, the problem was probably from rust. in addition, i was told that since there has not been a recall for such a defect on the 1999 windstar, that this is my problem. in my opinion, i interpret this to mean that ford considers it acceptable for the structure of their products to have a usable life of less than 10 years. if that is the case, think of how many of our lives are at stake on a daily basis because of 9 + year old fords on the roads. my wife is driving a 2002 ford taurus. is my family safe in it? this problem had nothing to do with a lack of maintenance on my part. there was nothing i could have done to prevent this. so who is at fault? i have photos which show the break, and can send them to you if you would like to see them. also, i still have the windstar sitting in my yard, so if you need to inspect the structure failure, you can do so. *tr updated and added pictures on 07/23/08. *kb

Subframe gave out, engine dropped and car was towed to my home.i had just exited a highway going 55mph. i was driving the to car to attend a work related event early evening. i drove past the entrance and proceeded to turn around on the road. as i approached the intersection the van lost power. i stopped being able to steer and brake. i turned hard on the steering wheel to move off the road. i was able to pull into a turn lane and fortunately there was very limited traffic on the road. the car came to a full stop on its own and there was a loud scrapping noise coming from under the front of the car. i was towed to my home. the tow driver stated the " subframe had given away and was dragging on the ground. it required a flat bed truck to tow. my mechanic confirmed the subframe had collapsed . the cost to fix was prohibited and i was concerned about the safety of the vehicle i contacted ford about the problem and they responded that there was no recall at that time. the car remained in the driveway in the event there was a recall on the vehicle for over one year. i finally decided to donate the car having not been contacted by the manufacturer. i was contacted that there was a recall identifying the problem in 2011 i am filing this complaint due to the fact that i was financially disadvantaged by the delays of the manufacturer to identify and notify me of the recall in a timely fashion. *tr

Without warning, while stopped at an intersection there was a clunk from the front passenger side of the van. when moving off from a stop, the steering wheel was suddenly 2"-3" off of center, down to the right. drove home and parked the van. mechanic came to inspect and found the subframe assembly holding the engine and transmission had failed, it had cracked through and no longer held the weight of the engine and transmission. he recommended not driving the vehicle due to the danger of the opposite side failing and causing major damage, extreme repairs and possible injury if occurring at highway speeds or less. the dealer only cautioned against possible exhaust system damage if the other side failed. this was not bolts or nuts rusting, the main subframe assembly developed a crack and separated. i am having the vehicle repaired, estimated cost $1200 - $1400 depending on the difficulty of removing the assembly's bolts. i have never seen this part fail on a vehicle. 2 different mechanics attest to this. i have seen vehicle frames in junkyards 20 years old still intact. i do not believe that this part of a vehicle that is driven on paved roads only should ever fail in average use. i will save the part if you desire. i believe ford should pay for this repair. there are several complaints on your website and on www.mycarstats.com. *tr

1999 ford windstar subframe rusting and having to be replaced. van failed safety inspection because of a hole in subframe due to rust. total cost paid out of pocket in 2008 $1240.56. *tr

Paint peeling off 1999 ford windstar. *tr

1999 ford windstar - frame near passenger-side front axle is rusted out. driver's side not effected. *tr

I purchased a 1999 ford windstar a few months ago. i have had nothing but problems with it. in fact, i have spent more than half of what i paid for the vehicle in repairs in only 2 months. the reason for my complaint is that the most recent repairs have involved items that i feel are extreme safety concerns. 1- the power doors on my vehicle to not lock/unlock properly, making it unable to open the sliding doors. this was looked at by the ford mechanic today. i was told that the door latches were bad and were "burning up" the door lock actuators. i'm not sure if this is the reason, but also lately, my door ajar light comes on my dash and the interior lights are coming on intermittently while driving. i have 3 children, two of them in car seats and unable to get them selves out of a car. i am concerned that if something were to happen such as an accident or an emergency situation that i would not be able to get my children out of the vehicle. i am paying to have this repaired at the tune of around $1,000.00 which i think is a real rip off, due to fords poorly manufactured vehicle. 2. my brake light stopped working on the left side of my van. i changed the bulb and tested it, and did not fix the problem. i then noticed that my rear tail light is now not working. i had this checked out by the mechanic today, and was told it is the rear electronic control module which is going to cost me nearly $600 to fix. i'm not sure what would cause such a thing to fail, but this is definitely a safety concern, where lights come into play. i could have been rear ended due to this malfunction. i'm beginning to wonder if ford is in the auto making/selling business, or the service business. it appears to me that they are poorly manufacturing vehicles only providing job security for the mechanics. please investigate this situation. any help in remedying this and getting ford to pay for their mistakes would be greatly appreciated. *jb

Frame rust