Problems with 2002 Ford Windstar SUSPENSION

Suspension:rear:axle cracked where recall part was installed. *tr

While driving my van i heard a very loud noise and my driver's side tire immediately went flat. i was able to pull the vehicle safely to a stop along the side of the road. i called a tow truck and had my vehicle looked at by the mechanic who informed me that a coil spring around my strut broke which caused my tire to be sliced open from the inside of the tire. i was very lucky i was not going any faster when the spring broke and sliced my tire open. i reviewed issues online that other people were having relating to my issue regarding the make and model of my vehicle. apparently ford had a recall on the windstar coil springs from a different year of the ford windstar vans due to the very same problem with the coil springs breaking and causing the tire to be punctured or sliced open from the inside. i am also very concerned after reading that the part had to fail before it would be addressed. it seems that if there is a safety recall it should be completed before a failure occurs and not after. this could have caused a very serious accident had i been on an interstate or even if i were going 55 miles per hour on the highway. i did contact ford motor company regarding this issue and was told that ford would not assist with the repairs because my vehicle was not recalled for this issue. i own two ford vehicles and i could not believe that my issue was not of a concern to ford. i probably will not buy another ford because of this. my family's safety has to come first and i am not convinced we will be safe if the company won't address these types of safety issues. *tr

We were driving around town and we heard a clunking sound in the back of the van. we took the van into the shop where they discovered a crack in the rear axle. luckily this did not happen the week before, as we were driving many highway miles or it could have been worse. this was a recalled part and it was taken in at the time of the recall. two different mechanics in town assured us that it was not our fault but that it was a faulty part. we take good care of our cars. we called ford directly thinking that they would honor their vehicle and fix a part they knew would break down. they gave us the run around and then never returned our phone calls. this van would had many good years left in it, now it can not be driven! *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that while reversing, a loud abnormal noise was coming from the rear of the vehicle. the contact discovered that the rear axle was fractured. the vehicle was taken to an independent mechanic, who confirmed that the axle was fractured. the vehicle was not repaired. the manufacturer was notified of the failure. the contact was informed that the vehicle was not included in the nhtsa campaign number: 10v385000 (suspension). the failure mileage was 155,000.

The sub frame mounts broke disconnecting the steering losing control. we drifted across the intersection and stopped the vehicle as far off the road as possible with the back end still in a lane. *js

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 30 mph, the rear axle fractured. the vehicle was taken to a dealer. the technician diagnosed the rear axle assembly needed to be replaced. the vehicle was repaired. the manufacturer was made aware of the failure. the failure mileage was 113,722 and the current mileage was 113,762.

I heard a loud popping noise coming from the back of my van. took it to the repair shop and learned the rear axle had a large crack and was almost broken in half. ford has a recall in effect for 2002 ford windstar's for axles that are cracking/breaking (nhtsa campaign number: 12v195000); however, ford is saying that my vin number is not a part of their recall even though i have a 2002 ford windstar. i had the rear axle welded to repair the crack. this was on the passenger side of the axle. i started hearing popping sounds again, returned to the repair shop only to learn the axle is now broken on the driver side of the axle. this is a serious situation and i feel since ford has a recall on this issue that my vehicle should be included. i am afraid to make another repair since the axle may still crack again. please contact ford to make them include all effected 2002 ford windstar vehicles before someone gets seriously hurt!! *tr

Tl* the contact owns a 2002 ford windstar. the contact stated while driving approximately 25 mph, a loud squeaking noise was emitted outside the vehicle and immediately after there was a strong smell of burning rubber released. the vehicle was taken to a dealer who stated that the rear axle fractured. the manufacturer was notified of this defect. the approximate failure mileage was 118,000.

Rear axel broke. there has been a recall on this part of the model van. i did take my van in to the "fix" 10/2011. the "fix" did not work. luckily, i was in town doing errands by myself when this happened. *tr

Rear axle complete fracture separation on drivers side last night 6/4/14 on my ford windstar limited edition, 2002. ford dealer did inspection 3 1/2 years ago as per recall 10s13. it passed inspection according to them (no cracks). 6 months later, they completed the recall procedure by reinforcing the axle in two places (according to manufacture's recommendation as per dealer). vehicle was towed back to dealer who inspected it and sent photos to ford manufacturer. ford refuses to cover the cost (as per the dealer) because recall work was done and vehicle is too old. i called ford manufacturer to object and ask for reconsideration. rep who answered cannot go against decision. i asked to speak to a supervisor. he said one will contact me within 2 hours. i received no call as yet. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 15 mph, the rear axle fractured. the vehicle was not taken to a dealer. the manufacturer was made aware of the failure. the failure and current mileage was 80,000.

I lost control on the highway i was driving i hit a pothole and my car when its own way i was coming home from the hospital from just giving birth two day earlier and i kept hearing a weird noise so i took my car to the shop and they said it was the lower control arm. *tr

Ford found that the rear axle had a hole in it causing the axle to shift to the right. recall work was done a few years ago. they said it was my fault and would not pay. abs and traction control light come on however reset when restarted. as of today they don't go off. *tr

After driving approximately 60 miles on rt 95 through boston ma to visit family - i noticed that the car was driving erratic, i wrongly attributed it to it being a windy day - when we arrived home we checked the car for possible problem - that is when my wife noticed that the rear tires were leaning inward - i slid under the rear of the car and noted that the rear axle had cracked - using my wife's car i went to the ford garage and explained the problem - the service manager asked me to bring it in and they would evaluate the problem. after looking at the car they told me it was unsafe to drive as a result of a cracked axle - by this time i had done a little research on the internet and found that ford had recalled that particular car for a cracked axle - i told the service manager about the recall - he stated that there was no such recall - i then returned home and emailed the service manager a copy of the ford corporation recall safety notice 10s13 - they contacted me the next day and told me that the warranty (windstar safety recall 10s13) would cover the part but not the labor because ford corporation had already fixed my car under that particular recall - and they were doing a good will gesture by paying for the part. the bill for the labor was $450.00. plus a loner car was refused as the car was being repaired. the last paragraph of the (windstar safety recall 10s13) states - ford dealers at no charge to customers will reinforce the axles of the affected vehicles as parts are available. if it is determined the axle can't be reinforced, it will be replaced as soon as parts are available. ford will provide for rental vehicles for customers until the rear axle of their vehicle has been replaced. i don't know where else to turn - i was hoping your organization could send a notice to hampton ford hyundai in north hampton nh and ask them to honor the recall...updated 06/04/2014 *bf the consumer stated the brackets were not installed properly. the manufacturer offered to pay for the axle and suggested the de

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 55 mph, she hard a loud popping noise. the contact had the vehicle towed to the dealer, who stated that the axle was cracked and needed to be replaced. the vehicle was not repaired. the manufacturer was notified of the failure. the failure mileage was 111,000.

Tl* the contact owns a 2002 ford windstar. the contact stated that the while traveling various speeds, the rear axle failed. the contact also mentioned that the vehicle was previously repaired under nhtsa campaign number 10v385000 (suspension). the vehicle was not repaired. the manufacturer was contacted about the failure. the failure mileage and vin was not available.

Tl* the contact owns a 2002 ford windstar. while driving at 30 mph, the contact noticed a burning rubber odor. in addition, the contact stated that the rear driver side wheel was leaning inward. upon further inspection, the contact noticed that the driver side rear axle was fractured. the vehicle was not diagnosed or repaired. the manufacturer was notified of the failures and stated that the vehicle was previously repaired under nhtsa campaign number: 10v385000 (suspension). the failure mileage was 92,500. updated 04/13/15*lj the consumer stated the vehicle's axle support is susceptible to rusting as well. the dealership advised the only way they would repair the vehicle would be if nhtsa issued a second recall. the consumer completed the repairs himself. updated 11/12/2015 *js

Tl* the contact owns 2002 ford windstar. the contact stated that the odor of burning rubber was present. the contact discovered that the rear axle had fractured through the reinforcement bracket and damaged the rear driver's side tire. the vehicle was diagnosed by the dealer but not repaired. the contact stated that in october 2010 a reinforcement bracket was installed on the rear axle of the vehicle in response to nhtsa campaign number 12v195000(suspension) but the defect still occurred. the manufacturer was notified and no solution was offered. the failure mileage was 92,000.

The rear axle beam cracked completely and fell to the ground causing me to lose control. i then moved it out of the flow of traffic and noticed the left rear tire was rubbing up against the inner well. unfortunately i was 60 miles from home and had to have it towed back to my house. in lost a days work due to the damage. i have owned the vehicle since 11/2011 and i purchased it with 79006 miles. *tr

Driven heard a snap stop and look it was rear axel cracked. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving at 50 mph, the rear or the vehicle collapsed. the contact also mentioned that the abs warning light illuminated. the vehicle was towed to the dealer who informed the contact that the rear axle had fractured due to rust and the abs master relay sensor had malfunctioned. the vehicle was not repaired. the manufacturer was made aware of the failure. the failure and current mileage was 140,000. the vin was unavailable.

Tl* the contact owns a 2002 ford windstar. the vehicle was included in and repaired under nhtsa campaign number: 12v195000 (suspension). the contact was driving approximately 65 mph when the rear driver's side tire blew shortly after the recall repair. the vehicle was towed to an independent mechanic for diagnosis, who stated that the axle was fractured. the mechanic replaced the axle shaft, break hose lock clips, the wheel, rear brake hose and the rear shocks. the manufacturer was not made aware of the failure. the approximate failure mileage was 140,000.

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving approximately 20 mph, she was alerted that both rear wheels were slightly turned inward. the vehicle was towed to an authorized dealer, who informed the contact that the rear axle was fractured. the vehicle was repaired under nhtsa campaign id number:12v195000 (suspension) in 2012. the remedy repair failed to correct the problem. the vehicle was not repaired for the recent failure. the manufacturer was notified of the defect. the approximate failure mileage was 70,000. the vin was unavailable.

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 35 mph, she heard a loud noise as the vehicle began to bounce and roll. the vehicle was towed to an independent mechanic for diagnosis and the contact was informed that the axle would need to be replaced. two years prior, the vehicle was repaired under nhtsa campaign number: 10v385000 (suspension). the manufacturer was notified of the failure. the vehicle had not been recently repaired. the vin was unavailable. the failure and current mileage was 161,000.

My parents had recall 11s16 performed on their windstar on march 20th 2012. a vibration had been felt since jan of 2013. they had new tires installed and balanced. problem persisted. i removed both front rims and inspected suspension. passenger side lower control arm nut missing from bolt. grade 10.9 metric bolt loose and partially backed out, unbelievably, washer still sitting on frame. inspected drivers side of vehicle and problem becomes apparent. multiple washers are stacked under head of bolt and under nut making full thread engagement impossible. multiple phone calls to ford and dealership. the dealership is adamant that instructions stipulate "multiple shims" must be used, "up to six depending". a "gauge" is used during the install process. i request a copy of installation instructions but dealership says they don't have any. i request the same from corporate ford but they don't have any??!!?? how does ford perform the repairs from "instructions stipulating" and use "up to six shims" and then "gauge" if they do not possess instructions??!!?? possible fixes: remove washer from under the head of the bolt but still use the one under the nut, use a lower height nut, use a longer bolt. all possible fixes make the repair much safer. ford refuses all suggestions and puts my family back on the road and at risk. multiple photos of properly repaired control arm kits are on the internet and all show proper thread engagement of the nut on the bolt. to keep my family safe should i do the repairs myself or do i put myself at legal risk? *jb

We were slowing to pull up to our home. we were driving about 10 mph. about 70 feet from our home. it sounded like there was a flat tire with rubbing and bumping noises. we parked on the street in front of our home. upon inspecting the vehicle, the tires were intact. the tires are bowing in. we looked under the rear of the car. we saw a large crack of the rear axle closer to the driver's side of the car. ford recalled the rear axle for this very reason 3 years ago due to corrosion caused by years of exposure to salted roads. ford performed the recall work by placing a bracket on the axle. the brake on our axle occurred under the bracket. ford is not assuming responsibility even though the supports they placed on the axle failed to do their job. there are other complaints this year for this same problem. the big difference between all the broken axles this year were the speed of the vehicles and type roads they were traveling on. i believe that there more out there that have had this same problem that have not been reported to this website yet. i also believe that more axles that have already received the recall fix are going to find their axles breaking in the near future as well. as for now the recall of these axles, ford has closed the case until forced to reopen the recall. ford should replace the entire axle on all the windstars that were under the original recall. *tr

Rear axle broke in half as i was turning a corner at very low speed, causing to loose control of vehicle and run off road. *tr

2002 ford windstar axle repair failed. golf mill ford in niles, il repaired my ford windstar in late 2010 after inspecting it. golf mill decided to patch and not replace the axle. on july 6 the tire kicked out and started to slide in patch bracket. i called ford and they instructed me to take to original dealer who done repaired and to keep all receipts for work done for possible reimbursement. dealer looked at axle and said they have had similar field problems and ford has been replacing the axle and repaired had internal code stating they axle repair did not "expire". when the repair request was submitted to ford for authorization, ford declined. the service manager was shocked and i was told that ford said the program was declined for the program met its obligation and i was told to keep the receipt for it would be necessary for future reimbursements. golf mill ford in niles, il made the repair and "good deal" labor rate to assist in the bill and for this i thank them. however, i am shocked the ford is aware of field failures in a poorly designed field fix and has chosen not to properly remedy the first attempt at a fix. i have pictures if necessary! *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that the vehicle received the recall repair for nhtsa campaign id number: 12v195000 (suspension) and indicated that the reinforcement bracket on the rear axle did not support the frame and the reinforcement bracket fractured as well as the rear axle. the vehicle was not repaired and was towed to the contacts residence. the manufacturer was notified of the failure. the failure mileage was not available.

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 10 mph, the vehicle squeaked while completing a turn. the vehicle was not repaired and the manufacturer was notified. the approximate failure mileage was 167,000. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated his vehicle was included in the recall under nhtsa campaign number: 12v195000 (suspension). after the recall repair was performed, the rear driver's side tire was banging against the frame. additionally, the steering wheel was difficult to control. the vehicle was inspected by an independent mechanic. the mechanic noticed a crack in the bracket that was installed under the recall and the axle had shifted out of the bracket. the manufacturer was made aware of the failure. the vehicle was not repaired. the approximate failure mileage was 223,080. *tr

Driving 20mph down a road and noticed a load noise. got out of the car and saw the tire inward, looked underneath and saw the rear axle was cracked. took it in for the recall in 11-10 and the dealership coated it. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 20 mph, he heard a loud bang. the contact exited the vehicle and noticed that both rear tires were tilted inward. the vehicle was towed to the dealer for inspection and they stated that the axle had failed and needed to be replaced. the vehicle was not repaired. the manufacturer was notified. the failure mileage was 133,000. the vin was unavailable.

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 70 mph, the rear axle fractured. the contact was able to move the vehicle onto the road shoulder and drove the vehicle into a ditch for safety. the vehicle was then towed to the dealer, who replaced the rear axle. the contact also stated that the fractured axle caused damage to the air conditioning line, speedometer and cruise control system. the manufacturer was made aware of the failure. the approximate failure and current mileage was 204,000. kmj

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving at various speeds, he heard several popping noises and then the rear wheels wobbled. after parking the vehicle at his home, he noticed that the rear axle had fractured. the contact was informed of a recall for nhtsa campaign number: 10v385000 (suspension). the manufacturer was notified but stated the vin was not part of a recall. the vehicle had not been repaired. the failure and current mileage was 138,800. updated 5/15/13 *cn the consumer stated this vehicle can not be driven. it should have been included in the recall. updated 05/28/2013 *js

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving 5 mph, the front passenger side wheel became detached from the vehicle. the vehicle was towed to an independent mechanic for diagnosis and the contact was informed that the bolt that connects the lower control arm to the front end cradle had become rusted. the contact was informed of nhtsa campaign number: 12v194000 (suspension). the dealer was notified and stated that the recall repair had already been done two years prior. the manufacturer was notified but offered no assistance. the vehicle had not been repaired. the failure and current mileage was 74,000. updated 04/09/13*lj the consumer stated ford motor company, did not repair the vehicle the correct way. the consumer stated the vehicle fixed the vehicle in a cheap and quick manner. the consumer believed the front end and lower control arm should have been replaced, instead of adding brackets. the left front wheel was not connected to the vehicle. the consumer was informed the front end cradle was completely rusted through and should have been replaced.

I was driving down the road when i noticed my 2002 ford windstar was swaying like it did the first time when the axle broke and it was replaced and then that one was reinforced. i stopped and looked under the rear-end and saw what looked like a crack or break, maybe two on the right side or drivers side of the axle. i immediately took the vehicle to the ford dealership for inspection and was told my axle was broken. so now the original axle broke and was replaced. that axle was reinforced, and now has also broken. something needs to be done. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that vehicle was included in and repaired under nhtsa campaign id number: 12v195000 (suspension). after the recall repair was performed while the contact was driving approximately 35 mph, the driver heard a loud scrapping from the vehicle. additionally, there was smoke coming from under the vehicle as the steering wheel began to jerk and shift abnormally. the manufacturer was made aware of the failure. the vehicle was not repaired. the vin was not available. the approximate failure mileage was 180,000.

Tl* the contact owns a 2002 ford windstar. the contact stated that while driving approximately 40 mph, the steering seized. the failure was recurring. the vehicle also shook violently and became unstable. the vehicle was taken to an independent mechanic where it was diagnosed that the rear axle needed to be replaced however, the part was not available to make the repairs. the manufacturer was notified of the failure and advised that the vehicle was not included in nhtsa campaign id number: 12v195000 (suspension). the approximate failure mileage was 178,000.

I have a bad vibration when im goin on the highway and when i hit bumps it makes a clunking sound and when i turn and makes a noise. *tr

I had my front tire replaced and the man that changed it told me that i need an alignment because of the way my tire wore out. about 3 weeks later, when i had the money, i took my car to get an alignment and the car shop called and said that both of my tire rods needed to be replaced before an alignment was completed. i've had the car for less than 2 years and although it is an older vehicle, the tire rods should have lasted longer than that (if properly checked). my steering shakes horribly from side to side at various speeds and often times my abs/trac off lights come on and won't got off. i am still able to use my brakes though. i am not sure why that light comes on. *tr

At times when is col,d the abs and brake light is off while driving, when it gets hot the abs and brake light turns on and the abs fails to work. code c1185 abs power relay output circuit failure. i got to a stop sign and the road was wet and the van skidded , the abs did not work. no one was hurt and i have seen all the complaints that ford owners are having. i don't know if my 2002 ford windstar had all the other recalls done, like the brake pressure differential deactivation switch (scds) and the rear frame welds that are breaking up on the chassis of many ford owners. i would like to verify what has been done to my ford windstar that i bought two months ago. i just had the inner and outer tie rod ends done along with the sway bar links at the front suspension.

My girlfriend was driving the car and with no warning the rear axle just snapped in half. ford says it was fixed by the previous owner and that the recall had expired and now i will have to pay out of pocket. well if it was reinforced and still snapped i believe the work was not done properly and ford should be responsible. she could have been seriously injured. *tr

The front driver side spring broke in two pieces. due to the weight of the vehicle the stabilizer bar ended up getting bent. also, because of the sharp edge where the spring broke it cut the front brake line. i'm grateful that it occurred overnight to where my family and i weren't driving it. *tr

To whom it may concern, i am seriously concerned about this vehicle and the way i am treated by ford motors. the car suddenly while driving on highway came to a complete stop and almost flipped. thank god that injuries were not that serious but the car is now total loss. after taking the car to private mechanics, it was determined that subframe broke and the axles, control arms all broke. it was then discovered that this was part of a recall. car was towed to ford motors dealership. a request has been made to provide me with safety report on the vehicle. ford and its dealership forced me out of their dealership and kicked me out. the car is their for months and i have been sending ford online messages via email and phone but they are not willing to buy the car or give me its value nor fix the car. i have been without a car for more than 4 months now and ford is not doing the least to even trade the car for another one. i am seriously disappointed. *tr

The van was parked in a parking lot, i was in the vehicle at the time. a noisy metal braking sound & movement of the van, made me think i was hit by another car, but no one was around. the front left coil spring broke, in more than 1 place. i had 15 minutes before been on a busy highway in a lot of traffic, i am just glad nothing happened then. on the 1998 ford windstar, i know there was a recall for the same problem. the 2002 ford windstar has had 2 other recalls, in regards to corrosion problems, on back axle & front frame. *tr

While driving approximately 30 mph the drivers side front coil spring broke in two and caused the tire to blow out. *tr

Tl* the contact owns a 2002 ford windstar. the contact stated that the rear axle cracked while driving 25 mph. the vehicle was taken to the dealer who advised the contact that there were no recalls for the vehicle. the manufacturer was notified of the failure who offered no assistance. the failure mileage was 180,000.

Tl* the contact owns a 2002 ford windstar. the contact stated while driving 5 mph there was a loud rubbing noise on the passenger side of the vehicle. after inspecting the tire he noticed the coil spring was rubbing and wearing down the tires. the tire was not punctured and he was able to drive the vehicle home without an incident. the manufacturer was notified of the failure and a claim was filed; yet, they offered no other assistance. the failure mileage was 70302.

Since i purchased this van from steuben/yates county pro-action in nys wheels to work program, i have had numerous problems with my ford windstar. 1st problem was with emission code stating it needed a map censor; 2nd issue was the sway bar broke (was repaired under recall at ford dealership in elmira, ny jan 2012). after numerous complaints to the car dealer ship i purchased the windstar from the garage, their mechanic replaced o-rings in the engine to fix the map censor in jan 2012 as well. in february 2014 i invested a little over 1,800.00 in repairs to my mechanic for; tune up, struts and shocks, brakes all around, wheel bushings, and a wheel alignment. i keep the van well maintained with oil changes and lately my radiator is loosing fluid. i always stop in where i maintain it and the business is always topping off the radiator fluid and when scheduled oil changes are due, i am always a quart low on oil. most recent incident: i will be driving along and the van turns off and turns back on while driving. at night when this would happen i have no headlights for a brief moment but that is still an unsafe van. also, i get an electric shocked every time i touch the van as i get in to go somewhere. ****this is my first and last ford!!**** *tr