2001 Ford Windstar Body & structure Problems

The contact owns a 2001 Ford Windstar. The contact stated while driving at various speeds and depressing the brake pedal, the front end of the vehicle made abnormal sounds. The vehicle was taken to an independent mechanic, where it was diagnosed that there was a fracture due to corrosion on the front sub frame. The mechanic related the failure to NHTSA Campaign Number: 11V030000 (Structure). The vehicle was not repaired. The dealer was notified of the failure and informed the contact that the VIN was not included in the recall. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 55,000.

NHTSA ID

11532671

Incident

Jun 17, 2023

Mileage

55,000 mi

Rear axle cracked in multiple locations causes car to sway and tires to turn inward and bald

NHTSA ID

11506431

Incident

Feb 9, 2023

The contact's husband owns a 2001 Ford Windstar. The contact stated that while in reverse, she heard an abnormal noise. No warning lights were illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the control arm was cracked. The contact was then informed by the mechanic of the NHTSA Campaign Number: 11V03000 (Structure). The dealer was notified of the failure and the contact was informed that no recall was affiliated with the VIN. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 70,000.

NHTSA ID

11492307

Incident

Nov 1, 2022

Mileage

70,000 mi

Car was in an single car accident. Steering and body damage. All fixed now. Need verification for salvage sticker.

NHTSA ID

11430793

Incident

Feb 12, 2020

THE AXLE WAS PART OF RECALL #11S16. AS PART OF THE RECALL THE AXLE WAS PATCHED, BUT THE AXLE IS NOW BROKEN BECAUSE THE "REPAIR" DID NOT CORRECT THE STRUCTURAL FLAWS IN THE AXLE.

NHTSA ID

11299013

Incident

Jan 13, 2020

Mileage

165,000 mi

WHEN I RECEIVED THE RECALL ABOUT THE POSSIBLE AXLE CRACKING DUE RUST I TOOK MY CAR IN AND HAD THE BRACKETS PUT ON AND THEN I RECEIVED A RECALL THE HAVE THE BRACKETS CHECKED WHICH I DID AND THEY WERE CORRECT. TODAY I TOOK MY VAN IN FOR PA INSPECTION AND WAS TOLD MY REAR AXLE ON THE DRIVERS SIDE HAD A CRACK IN IT WHICH YOU COULD SEE THROUGH THE OPENING OF THE BRACKET THEY INSTALLED. WHEN I ASKED THE MECHANIC IF FORD WAS GOING TO PAY TO REPLACE IT NOW SINCE THE BRACKET DIDN'T KEEP IT FROM CRACKING HE SAID NO. THEN I ASKED IF THE BRACKET WAS STRONG ENOUGH TO HOLD IT SO I CAN KEEP DRIVING, HE SAID HE WOULDN'T TRUST IT. I ONLY HAVE A 115,500 MILES ON IT, SO WHAT I'M BASICALLY BEING TOLD IS THE MINUTE THE RECALL WENT OUT I SHOULD HAVE HAD THEM REPLACE THE AXLE, INSTEAD OF THE STUPID BRACKETS WHICH WERE JUST BAND AIDS TO PLACATE UPSET OWNERS. I ONLY HAVE ONE CAR SO I HAVE TO DRIVE IT UNTIL I CAN AFFORD TO GET IT FIXED OR BUY ANOTHER CAR. I'M JUST ONE PERSON, HOW MANY MORE ARE FACED WITH THE SAME SITUATION. I ONLY HAVE UNTIL OCTOBER WHEN MY INSPECTION EXPIRES AND I'M PANICKING TRYING TO FIGURE WHAT I CAN DO. FORD KNEW THOSE BRACKET S AT BEST JUST BOUGHT THE OWNERS A COUPLE OF MORE YEARS BEFORE THEIR CARS COULD AGAIN BE A HIGHWAY HAZARD. IT'S STILL RUSSIAN ROULETTE IN MY OPINION THE AXLE AT A MINIMUM SHOULD BE REPLACE WITH A DISCOUNT TO THE ORIGINAL OWNERS.

NHTSA ID

11252329

Incident

Aug 29, 2019

THIS VAN LOOKS FINE ON THE OUTSIDE,BUT THE FRAME AND FLOOR ARE RUSTED OUT. I WAS DRIVING ON A CITY STREET WHEN THE BRAKES WENT OUT AND WHEN I TOOK IT TO BE REPAIRED THE MECHANIC AT CARLS BODY SHOP , WHERE IT WAS TI BE REPAIRED TOLD ME IT WAS BEYOND REPAIR AND UNSAFE TO DRIVE. THE VAN IS MADE TO TRANSPORT A WHEELCHAIR AND THE AREA WHERE THE WHEELCHAIR IS RUSTED THE WORST. THE MECHANIC ALSO TOOK PICTURES OF THE UNDER BODY TO SHOW ME HOW BAD IT REALLY WAS.

NHTSA ID

11206940

Incident

Mar 7, 2019

Mileage

2 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT STATED THAT DURING A ROUTINE CHECK-UP, AN INDEPENDENT MECHANIC DIAGNOSED THAT THE SUB-FRAME WAS COMPLETELY CORRODED. THE VEHICLE WAS TOWED TO THE COLONIAL FORD, INC DEALER (508-746-3400, 147 SAMOSET ST, PLYMOUTH, MA 02360) WHERE IT WAS CONFIRMED THAT THE SUB FRAME WAS ROTTED OUT. THE TECHNICIAN, HOWEVER, STATED THAT THERE WAS NO RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THERE WAS NO RECALL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 106,031.

NHTSA ID

11206518

Incident

Apr 25, 2019

Mileage

106,031 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING AT 35 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE BRAKE PEDAL DELAYED IN RESPONDING. THE CONTACT MENTIONED THAT WHEN ATTEMPTING TO PARK, THE BRAKE PEDAL TRAVELED TO THE FLOOR BOARD. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE VEHICLE WOULD NEED TO BE TOWED TO ANOTHER SHOP IN REGARDS TO IT BEING A MODIFIED VEHICLE. THE VEHICLE WAS THEN TOWED TO ANOTHER INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT SAFE TO DRIVE AND THAT THE FRAME WAS RUSTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 38,000. *JS

NHTSA ID

11206493

Incident

Apr 15, 2019

Mileage

38,000 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. WHILE THE VEHICLE WAS UNDERGOING A ROUTINE CHECK-UP AT AN INDEPENDENT MECHANIC SHOP, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS RUSTED. THE CONTACT WAS ADVISED NOT TO DRIVE THE VEHICLE. THE VEHICLE WAS TAKEN TO BENNA FORD SUPERIOR (715-394-8669, LOCATED AT 3022 TOWER AVE, SUPERIOR, WI 54880) WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS RUSTED OUT AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE AND STATED THAT THE FAILURE WAS DUE TO THE AGE OF THE VEHICLE AND THE MILEAGE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 250,000.

NHTSA ID

11197204

Incident

Apr 10, 2019

Mileage

250,000 mi

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.

NHTSA ID

11182225

Incident

Jan 24, 2019

Mileage

132,596 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT STATED THAT THE DEALER (GURLEY LEEP FORD LINCOLN, 320 E IRELAND RD, SOUTH BEND, IN 46614, (574) 291-6910) INDICATED THAT THEY SERVICED AN UNKNOWN RECALL FROM THE MANUFACTURER FOR THE REINFORCEMENT BRACKETS AND THAT THEY HAD NOT BEEN REQUIRED TO PROVIDE ANY ADDITIONAL REPAIRS. THE DEALER REPLACED THE REAR AXLES DUE TO THE REINFORCEMENT BRACKETS FRACTURING WHILE THE VEHICLE WAS BEING DRIVEN BELOW 25 MPH. THE DEALER STATED THAT THEY WERE NOT REQUIRED BY THE MANUFACTURER TO REINSTALL REINFORCEMENT BRACKETS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND SUGGESTED REPLACING THE SAME OEM REAR AXLES. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS NOT AVAILABLE. *TT CONSUMER STATED I FEEL THE REAR AXLES FAIL EVEN WITH THE RECALL BRACKETS ON, SO I FEEL FORD SHOULD PAY FOR THE BILL. THE TIRES WENT BAD AND OUT WHEN THIS HAPPENED. THE RECALL DID NOT WORK AND PUT NEW RECALL PARTS ON NEW AXLES. UPDATED 10/16/18*JB

NHTSA ID

11118990

Incident

Apr 1, 2015

Mileage

122,983 mi

REMOVED SUBFRAME TO REPLACE FAULTY TORQUE CONVERTER. FOUND SUBSTANTIAL RUSTING AT FIREWALL END OF SUBFRAME ON BOTH "ARMS", REQUIRING REPLACEMENT OF SUBFRAME. CALLED LOCAL DEALERS, NO "OPEN" RECALL (OVER 15 YEAR-OLD VAN) AND $4,900 NEW SUBFRAME QUOTE PROVIDED, WITH NO DEALER OR MANUFACTURER COVERAGE, AFTER CALLING NATIONAL AND CANADIAN MFCTR RECALL NUMBERS. MFCTR/DEALERS OF NO ASSISTANCE, WHATSOEVER. PART NOT ACTUALLY AVAILABLE.

NHTSA ID

11093526

Incident

Mar 1, 2018

Mileage

104,000 mi

THIS VAN WAS RECALLED FOR KNOWN ISSUES WITH THE REAR AXLE CORRODING. THIS RECALL INVOLVED INSTALLING SUPPORT BRACKETS ON THE AXLE. THE AXLE HAS NOW CRACKED ALMOST ALL THE WAY THROUGH NEXT TO THE BRACKET. THIS HAPPENED WHILE GOING OVER A SPEED BUMP SLOWLY. FROM MY RESEARCH ONLINE, THIS SEEMS TO BE A COMMON ISSUE WITH THE REPAIR THAT WAS ISSUED IN THIS RECALL.

NHTSA ID

11083715

Incident

Apr 6, 2018

Mileage

140,000 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE DEALER (RUSS MILNE FORD, 24777 HALL RD, MACOMB, MI 48042, (877) 821-8648) INDICATED THAT A RECALL REMEDY WAS PROVIDED FOR THE REPLACEMENT BRACKETS BEFORE THE CONTACT OWNED THE VEHICLE. WITHIN A YEAR OF OWNING THE VEHICLE, THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT A RECALL HAD ALREADY BEEN PROVIDED. ALTHOUGH THE CONTACT INFORMED THE MANUFACTURER THAT THE RECALL REMEDY FAILED TO CORRECT THE FAILURE, THEY STATED THAT THE CONTACT WOULD NEED TO REPAIR THE VEHICLE. IN ADDITION, THE ENGINE CRADLE WAS COMPLETELY RUSTED TO THE POINT OF FRACTURING, CAUSING SHAKING AND A STRONG VIBRATION. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11058294

Incident

Nov 2, 2015

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. WHILE STATIONARY, THE CONTACT NOTICED THAT THE FRONT ENGINE CRADLE OF THE VEHICLE WAS SEVERELY RUSTED AND CORRODED. THE CONTACT STATED THAT THERE WERE HOLES IN THE ENGINE CRADLE. MATTHEWS FORD OREGON IN OREGON, OHIO WAS MADE AWARE OF THE FAILURE AND STATED THAT THERE WAS NO RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS 190,000.

NHTSA ID

11055474

Incident

Nov 1, 2017

Mileage

190,000 mi

SUB FRAME

NHTSA ID

11032745

Incident

Oct 10, 2017

Mileage

141,588 mi

I WAS DRIVING AT AROUND 30 MPH, 2 CARS IN FRONT SLAMMED ON BRAKES, I WAS APPROXIMATELY 1 1/2 CAR LINKS BACK AND HIT THE BRAKES. ABS FAILED, AIRBAGS FAILED, AND SLID INTO CAR IN FRONT OF ME. I WAS ON A CITY STREET GOING STRAIGHT.

NHTSA ID

11023381

Incident

Aug 26, 2017

Mileage

86,000 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. WHILE DRIVING 5 MPH, THE SUBFRAME COMPLETELY FRACTURED AND FELL APART WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC (SPIELMANN SERVICE CENTER MN; 952-546-0508) WHERE IT WAS CONFIRMED THAT FORD WOULD NOT PAY FOR THE DAMAGE. THE VEHICLE WAS TOWED TO THE DEALER (LUTHER NORTH COUNTRY FORD, LOCATED AT 10401 WOODCREST DR NW, COON RAPIDS, MN 55433; (612) 424-7648) WHERE IT WAS DIAGNOSED THAT THE ENGINE, TRANSMISSION, AND DRIVE TRAIN NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AT 800-392-3673 AND STATED THAT ONLY THE SUBFRAME COULD BE REPAIRED FOR FREE, BUT THE DAMAGE FOR THE ENGINE, TRANSMISSION, AND DRIVE TRAIN WOULD HAVE TO BE PAID FOR BY THE CONTACT. A CASE NUMBER WAS NOT PROVIDED. THE APPROXIMATE FAILURE MILEAGE WAS 184,500.

NHTSA ID

11021449

Incident

Jun 23, 2017

Mileage

184,500 mi

TAKATA INFLATORS;I FORD DENYING MY REQUEST F VIN #[XXX] I HAVE AN OBVIOUS CRACK (SEE PHOTOS) DIRECTLY UNDER THE BRACKET A BAND-AID THAT FORD ISSUED IN AN EARLIER RECALL ON MY REAR AXLE WITH THE SOLE PURPOSE OF THIS BAND-AID TO PREVENT SUCH CRACKING. APPARENTLY MY BRACKET PART WAS DEEMED INSTALLED CORRECTLY, EFFECTIVELY CAUSING A DENIAL FOR A REPLACEMENT PART ON MY WINDSTAR. CLEARLY THIS BRACKET FAILED AND DID NOT STOP MY REAR AXLE FROM EXPERIENCING CRACKING! FORD CLEARLY NEW EXACTLY WHERE THIS CRACKING WOULD OCCUR BECAUSE THE CRACK APPEARS DIRECTLY UNDER THE BRACKET INSTALLED TO CREATE A STRONGER PART. THE ONLY THING HOLDING THIS REAR AXLE TOGETHER IS THIS BRACKET. THIS PARTICULAR PART IN QUESTION IS DIRECTLY BELOW THE GAS TANK, SHOULD THIS CRUCIAL PART EXPERIENCE FAILURE WHILE DRIVING ON A 70MPH HIGHWAY WHAT WOULD HAPPEN? ALSO LOOKING AT MY WINDSTAR ON A LIFT WE NOTICED THE CENTER OF THE WINDSTAR SEEMS TO BE SAGGING (SEE PHOTOS) FROM WHAT APPEARS TO BE THE UNDER CARRIAGE BREAKING DOWN FROM RUST AND CORROSION, THIS APPEARS TO BE CAUSING EXTREME STRUCTURE FAILURE. I DO RESIDE IN ONE OF THE STATED SALT BELT STATES AS BEING THE STATE OF IOWA. WHAT WOULD THE FULL CRITERIA FOR THIS RECALL AND BUYBACK PROGRAM ON CERTAIN WINDSTAR?S IN 2011 THRU 2013 BE? WHY WAS MY WINDSTAR LIMITED EXCLUDED IN THIS RECALL? I STILL HAVE NOT BEEN ADVISED NOT TO DRIVE MY WINDSTAR BY ANY CURRENT FORD REPRESENTATIVES. HOWEVER FORMER FORD MECHANICS HAVE ADVISED ME NOT TO DRIVE MY WINDSTAR, THESE SAME MECHANICS? ARE ADAMANT MY WINDSTAR IS UNSAFE! I HAVE BEEN ATTEMPTING TO FIX THE CONCERNS THAT MOFFITTS FORD IN BOONE IOWA WANTED ME TO REPAIR AT THE TIME OF THE AXLE INSPECTION. ONLY HAVING MORE CONCERN BROUGHT TO MY ATTENTION ABOUT THE AXLE. I WROTE [XXX] A LETTER 2/15/17 ASKING TO OVERTURN AND ALLOW REPAIR [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR *JS

NHTSA ID

10969784

Incident

Mar 31, 2017

Mileage

18,000 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT TOOK THE VEHICLE TO A DEALER FOR A RECALL RELATED TO THE LOWER CONTROL ARM. THE CONTACT STATED THAT THE REPAIR FOR THE LOWER CONTROL ARM WAS COMPLETED; HOWEVER, THE SUBFRAME WAS RUSTED. THE RUST WAS WITHIN THE CONNECTION BETWEEN THE CONTROL ARM AND THE SUBFRAME. THE DEALER DETERMINED THAT THE RUST WAS PART OF THE RECALL REPAIR THAT WAS COMPLETED. THE RECALL INFORMATION WAS NOT PROVIDED. THE FAILURE MILEAGE WAS 140,000.

NHTSA ID

10956367

Incident

Feb 15, 2017

Mileage

140,000 mi

I RECEIVED A SAFETY RECALL IN 2012 ABOUT THE SUBFRAME SUPPORTING THE MOTOR AND TRANSMISSION. FORD PUT TWO BRACKETS ON MY VEHICLE OVER THE RUST SPOTS. NOW THE FRAME HAS ALMOST RUSTED AWAY. MY MECHANIC SAID I SHOULD NOT DRIVE THE VEHICLE IN THAT CONDITION, IT IS NOT SAFE. INSTEAD OF REPLACING THE RUSTY COMPONENT FORD PATCHED IT. I STILL DRIVE THE VAN, IT HAS 138,000 MILES ON IT. I LIVE IN MINNESOTA WHERE RUST IS A PROBLEM. THE FIX WAS INAPPROPRIATE FOR THE AREA. UPDATED 07/20/2017*JS

NHTSA ID

10954815

Incident

Jan 30, 2017

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V608000 (STRUCTURE). THE VEHICLE WAS TAKEN TO THE DEALER WHO INDICATED THAT THE BRACKETS WERE INSTALLED PROPERLY, BUT FAILED TO PROVIDE A CORRECT DIAGNOSIS. THE CONTACT STATED THAT THE TIRE RUBBED AGAINST THE FRAME IN THE REAR AND FRACTURED THE REAR DRIVER'S SIDE BRACKET. THE VEHICLE WAS PARKED AT THE CONTACT'S RESIDENCE DUE TO THE FAILURE. THE DEALER WAS NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS UNKNOWN. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

10947599

Incident

Oct 13, 2016

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. THE CONTACT STATED THAT THE SUBFRAME WAS FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS CONFIRMED THAT THE FRAME FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS SERVICED PER NHTSA CAMPAIGN NUMBER: 15V608000 (SUSPENSION), BUT THE REMEDY FAILED TO REPAIR THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 141,302.

NHTSA ID

10926729

Incident

Nov 16, 2016

Mileage

141,302 mi

TL* THE CONTACT OWNS A 2001 FORD WINDSTAR. WHILE A RACK AND PINION WAS BEING INSTALLED ON THE VEHICLE, THE CONTACT WAS INFORMED BY THE SERVICE TECHNICIAN THAT THE SUBFRAME WAS CORRODED. THE VEHICLE WAS PREVIOUSLY REPAIRED PER NHTSA CAMPAIGN NUMBER: 11V030000 (STRUCTURE), BUT THE REMEDY FAILED TO REPAIR THE VEHICLE. THE CONTACT MENTIONED THAT THE PREVIOUS REPAIR WAS NOT ADEQUATE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10917324

Incident

Oct 19, 2016