1998 Ford Windstar

THIS INVESTIGATION IS OPENED TO ASCERTAIN FACTS CONCERNING THE PROBLEM EXPERIENCE, SCOPE, AND RATIONAL FOR ISSUING A TECHNICAL SERVICE BULLETIN TO CORRECT THE PROBLEM.HISTORICALLY, PREVIOUS SAFETY RECALLS INVOLVING SIMILAR TYPE OF FAILURE HAVE BEEN FILED WITH THE AGENCY.

In a letter dated August 26, 2010, Ford Motor Company (Ford) submitted a Defect Information Report notifying NHTSA that it will conduct a safety recall (NHTSA Recall No. 10V-385) to address a rear axle defect in model year (MY) 1998 through 2003 Ford Windstar vehicles built at the Oakville assembly plant from September 1, 1997 through February 28, 2003 and either sold or currently registered in high corrosion (Salt-Belt) states where the use of salt and other corrosive chemicals may be used to treat snow/ice covered roads.The following states are included in Ford's recall:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. The subject vehicles utilize a Stamped/Formed axle assembly manufactured by Benteler automotive Corporation of Galesburg, MI.According to Ford, after many years of vehicle service in the Salt-Belt states, corrosion can weaken the rear axle, making it susceptible to torsional stress.There is a risk that the combined effects of corrosion and stress can lead to cracks which, if undetected, can propagate and result in a complete fracture of the axle.A completely fractured axle can affect vehicle handling and increase the risk of a crash.To correct the safety defect, Ford will initially inspect all of the subject vehicles brought into Ford/Lincoln-Mercury dealerships for possible cracked axles.Owners of vehicles without cracked axles will be notified when to return for the installation of reinforcement brackets to extend the axle durability in the presence of corrosion.Owners who have vehicles with cracked axles will either be offered a repair or alternative transportation until parts become available. On May 13, 2010, the Office of Defects Investigation (ODI) opened PE10-016 to investigate complaints of rear axle cracking in MY 1999 through 2003 Ford Windstar minivans.Combining ODI and Ford complaint data, ODI is aware of a total 891 complaints alleging rear axle cracking in the subject vehicles.Over a third of the complaints (334) allege that the cracking progressed to a complete fracture of the rear axle, including 8 allegations of crashes resulting in 3 injuries. Approximately 57 percent of the subject vehicles (524,661) were sold in Salt-Belt states covered by Ford's recall and Ford estimates that approximately 463,000 of these remain in service.Ninety-six percent of the complaints (858) and all of the complaints alleging complete fracture were from the recall region.The action taken by Ford is sufficient to resolve the issues raised by this investigation.Accordingly, this investigation is closed.

EA08-021 IS CLOSED WITH FORD'S ACTIONS IN RECALL 09V-399 RECALLING APPROXIMATELY 4.5 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).WITH THIS RECALL FORD HAS NOW RECALLED ALL OF THE APPROXIMATE 16 MILLION FORD MODEL VEHICLES THAT WERE MANUFACTURED FROM MY 1992 THROUGH 2003 WITH A TEXAS INSTRUMENTS SCDS.NHTSA WILL CONTINUE TO MONITOR THE RECALLED VEHICLES TO ENSURE REMEDIES INSTALLED BY FORD TOMITIGATE THE POTENTIAL FOR SCDS RELATED FIRES ARE EFFECTIVE.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR FURTHER DETAILS.

ODI HAS RECEIVED 134 CONSUMER COMPLAINTS, 285 MANUFACTURER COMPLAINTS, AND 137 MANUFACTURER WARRANTY CLAIMS ALLEGING INCIDENTS OF ENGINE COMPARTMENT FIRE IN MODEL YEAR (MY) 1995 THRU 2003 FORD WINDSTAR VEHICLES.TWO OF THE ODI COMPLAINTS ALLEGE THE FIRES CAUSED STRUCTURAL DAMAGE TO THE COMPLAINANT'S HOME.OF THE 134 ODI COMPLAINTS, 36 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS PARKED, 72 ALLEGE THE FIRE OCCURRED WHILE THE VEHICLE WAS RUNNING AND 26 OF THE COMPLAINTS DO NOT SPECIFY IF THE VEHICLE WAS RUNNING OR NOT.FURTHER REVIEW OF THE ODI COMPLAINTS SHOWS THAT 72 ALLEGE THAT THE SPEED CONTROL DEACTIVATION SWITCH (SCDS) CAUSED THE FIRE AND 10 ALLEGE THAT THE SCDS LEAKED BRAKE FLUID ON TO THE ABS MODULE RESULTING IN THE FIRE.THERE WERE 52 THAT DID NOT IDENTIFY A CAUSE OR THAT IDENTIFIED MISCELLANEOUS OTHER CAUSES.ODI HAS ALSO RECEIVED 89 COMPLAINTS ( NOT COUNTED IN THIS RESUME) ALLEGING THAT THE SCDS DEVELOPED A BRAKE FLUID LEAK.THIRTEEN OF THESE COMPLAINTS SAY THAT THE LEAK AT THE SCDS RESULTED IN BRAKED FLUID REACHING THE ABS MODULE.THIS PE HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA) TO FURTHER EVALUATE THE CAUSE OF THE FIRES AND ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.

The contact owns a 1998 Ford Windstar. The contact stated while driving at various speeds, the vehicle was shuddering significantly. The vehicle was taken to a Tire Store, where it was diagnosed that the rear axle was corroded and had fractured from the upper side to the lower side. The mechanic related the failure to NHTSA Campaign Number: 10V385000 (Suspension). The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was unknown.

NHTSA ID

11552899

Incident

Oct 24, 2023

We woke up this morning to the driver's side completely burned and melted. It had been parked sinced Monday. Fire inspector said it was definitely an electrical issue coming from the seat.

NHTSA ID

11468285

Incident

Jun 8, 2022

TL* THE CONTACT OWNS A 1998 FORD WINDSTAR. WHILE DRIVING APPROXIMATELY 30 MPH, THE CONTACT HEARD A HISSING SOUND COMING FROM THE VEHICLE, BUT COULD NOT IDENTIFY WHERE THE SOUND ORIGINATED. THE CONTACT ALSO BEGAN TO SMELL A BURNING RUBBER ODOR. THE CONTACT PULLED INTO A NEARBY DRIVEWAY AND PLACED THE VEHICLE IN PARK. THE CONTACT WAS UNABLE TO IDENTIFY ANY FAILURES WITH THE VEHICLE. THE CONTACT CALLED A CERTIFIED MECHANIC; HOWEVER, THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT STATED THAT THE FAILURES WERE SIMILAR TO NHTSA CAMPAIGN NUMBER: 10V385000 (SUSPENSION). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 125,000.

NHTSA ID

11289706

Incident

Dec 16, 2019

Mileage

125,000 mi

SUBFRAME RUSTED ON LEFT FRONT PASSENGER SIDE. 1998 FORD WINDSTAR. I HAD A POPPING NOISE WHEN I MADE A LEFT TURN AND LOUD CRUNCHING NOISE AND STEERING WHEEL PULLED TO LEFT. I HAD TAKEN IT TO A AUTO SHOP AND THEY REPLACED STRUTS.SWAY BARS AND BRAKES . NO ONE TOLD ME ABOUT THE RUST ISSUE WITH THE SUB FRAME. I DROVE IT HOME FROM SHOP. SAME PROBLEM. RETURNED THE VEHICLE TO SAME REPAIR SHOP AND THE HAD A WELDER ATTACH STEEL BRACKET TO HOLD UP SUB FRAME. 2 DAYS LATER WORSE. I HAD A SECOND MECHANIC LOOK AT IT AND HE TOLD ME THE FIRST REPAIR SHOULD NOT HAVE ASKED ME TO REPAIR ANYTHING ON THE VAN. SUB FRAME IS FAILED AT 128,436 MILES. I NOTIFIED FORD MOTOR CO . OF THE FAILURE, WAS GIVIN A CASE NUMBER. ENGINE WILL FALL OUT OF BOTTOM WITH CORROSION OF SUB FRAME. VEHICLE IS NOT SAFE TO DRIVE

NHTSA ID

11257710

Incident

Sep 5, 2019

Mileage

128,000 mi

MY REAR AXLE BROKE AND THEN MY DOOR AJAR CONSTANTLY GOES OFF EVEN WHEN DOORS ARE CLOSED. THE AXLE BROKE REAR DRIVERS SIDE LEAVING ME STRANDED. I WAS DRIVING IN TOWN 20 MPH.

NHTSA ID

11172745

Incident

Jan 29, 2019

Mileage

160,000 mi

MY FRONT CRADLE AT STEERING AREA HAS COMPLETELY RUSTED INTO FROM AC LEAK AND ROAD SALT VAN WAS SOLD IN VERMONT NOW IS LOCATED IN VIRGINIA UNSAFE ALMOST UNDRIVABLE TO FORD DEALER FOR A REAR AXLE RECALL FOR AXLE BRACES PLEASE INVESTIGATE THIS

NHTSA ID

11091939

Incident

Mar 23, 2018

Mileage

30,000 mi

MY MINI VAN LIGHTS WOULD FLICKER WHILE I'M DRIVING AND EVEN AFTER REPLACING THE STARTER IN THE CAR, IT STILL TURNS OFF WHILE I'M DRIVING. THERE'S RUST COMING FROM UNDER THE CAR, I SMELL A BURNT SMELL WHEN I'M DRIVING. I'M HAVING ELECTRICAL ISSUES, MY CAR STOPS WHEN IT WANTS TO IN THE MIDDLE OF THE HIGHWAY, .. IT MAKES NOISES WHEN I'M TURNING, I HAVE RUST COMING FROM UNDER MY CAR. THE SIGNAL LIGHTS FLICKER. WHILE DRIVING THE WINDSHIELD WASHER, SEAT BELT, AND DOOR AJAR WARNING LIGHTS FLASH ON AND OFF. WHILE THIS IS HAPPENING THE WIPER BLADES STOP WORKING, FRONT BRAKE ROTORS IS CAUSING STEERING WHEEL TO SHIMMY WHEN THE BRAKES ARE APPLIED. NOW WHEN I TURN MY WHEEL TO THE LEFT, IT MAKES THIS LOUD NOSE. WHAT IS THAT?!

NHTSA ID

11090769

Incident

Aug 2, 2017

ABS DASHBOARD LIGHT STAYS ON VIBRATION WHEN BRAKING WHILE IN MOTION VIBRATION IS PROPORTIONAL TO SPEED

NHTSA ID

11073153

Incident

Jul 1, 2015

Mileage

200,000 mi

For 1999-2003 Windstar vehicles Safety Recall 11S16 has been issued for vehicles that are operated in high corrosion areas for an extended period, where a front subframe lower control arm (LCA) rear attaching flange or rear body mount could separate from the vehicle subframe. Separation of one LCA attachment or both rear body mounts may result in a loss of vehicle directional control, increasing the risk of a crash.

Safety recall 10S13 - Rear axle corrosion - requests for recall service action

For 1998-2003 Windstar vehicles Safety Recall 10S13 has been issued for vehicles that are operated in high corrosion areas for an extended period, where the rear axle could potentially fracture. If the rear axle should completely fracture, vehicle handling may be affected which could increase the risk of a crash.

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

FORD: SAFETY RECALL CONCERNING REAR AXLE FRACTURING IF VEHICLE IS OPERATED IN HIGH CORROSION AREAS FOR AND EXTENDED PERIOD. MODEL 1998-03 WINDSTAR. *PE

FORD: ON SOME MINIVANS, REAR AXLE WILL FRACTURE, IN HIGH CORROSION AREA, AFTER OPERATING FOR AN EXTENDED TIME PERIOD, AND VEHICLE HANDLING ABILITY WILL BE AFFECTED. MODEL 1998-2003 WINDSTAR. *PE