2002 Ford Windstar Engine Problems

Manufacture Recall # 09S09 NHTSA Recall # 09V399000 Instrument cluster has become faulty. Details listed below. Overdrive (O/D) light will randomly start flashing for no reason ABS will randomly engage Parking brake light will randomly turn on Speedometer with become sporadic Transmission has trouble shifting gears due to tachometer becoming sporadic Vehicle will randomly try to die/stall out at a prolonged stop or while coming to a stop, even after all charging components have been replaces i.e. battery, alternator, drive belt, and cables.

NHTSA ID

11655566

Incident

Oct 23, 2024

The contact owns a 2002 Ford Windstar. The contact stated while driving 60 MPH, the vehicle was wobbling uncontrollably and almost caused an accident. No warning light was illuminated. The vehicle was towed to an independent mechanic. The vehicle had been diagnosed by an independent mechanic. The contact was informed that the rear axle needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure and provided no assistance. The failure mileage was approximately 142,000.

NHTSA ID

11546076

Incident

Aug 25, 2023

Mileage

142,000 mi

The gauges are acting crazy which causes the engine to jerk or the transmission and then it starts making the lights flicker in the interior and the gauges start sticking. It seems to make the overflow on the radiator to empty more because it is causing the sensors in the electrical for the parts to go crazy and run hot. Sometimes it only does it every so often but after getting the reserve hose on the power steering that connects to the reservoir to the coolant the battery was drained. Then going after getting it charged down the highway it caused the interior lights radio and seat and turn signals not to work when coming to a complete stop and it was idling the dashboard and all the lights were coming back on once given a guess it winded up not working again causing the battery to become hot or warm and acid you can smell in the air like rotten eggs. It is causing the overflow tank of the radiator to evaporate more or come out quicker and it is causing other component parts to react strangely which I'm afraid will cause a fire in the vehicle and the idling is not correct also on it now

NHTSA ID

11495403

Incident

Nov 29, 2022

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. WHILE DRIVING AND APPROACHING A STOP LIGHT, A LOUD NOISE OCCURRED AND THE VEHICLE ACCELERATED AT A HIGH SPEED. THE CONTACT DEPRESSED THE BRAKE PEDAL, BUT COULD NOT GAIN CONTROL OR STOP THE VEHICLE. THE STEERING WHEEL BECAME LOOSE AND THE CONTACT QUICKLY SHIFTED INTO PARK. THE CONTACT POWERED OFF THE ENGINE. WHEN THE VEHICLE WAS RESTARTED, THE ENGINE REVVED HIGH. THE CONTACT POWERED OFF THE ENGINE AGAIN, EXITED THE VEHICLE, OPENED THE HOOD, AND NOTICED THAT THE SERPENTINE BELT WAS SHREDDED. ALSO, THE METAL PULLEYS WERE CRACKED IN SEVERAL PARTS AND SOME WERE MISSING. THE CONTACT NOTICED UNDERNEATH THE VEHICLE THAT THE MOTOR, SUBFRAME, AND MUFFLER WERE LAYING ON THE GROUND. A TOW TRUCK WAS CALLED AND THE DRIVER STATED THAT THE SUBFRAME GAVE OUT. THE VEHICLE WAS TOWED TO THE CONTACT'S MOTHER'S RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V030000 (STRUCTURE). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURES. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.

NHTSA ID

11245856

Incident

Aug 22, 2019

Mileage

140,000 mi

ABS LIGHT AND TRACTION CONTROL LIGHT ILLUMINATES AFTER DRIVING FORWARD 150 YARDS. HEAVILY SALTED CHICAGO STREETS HAVE CAUSED CORROSION UNDER CAR. SUSPECT ABS FAILURE DUE TO SALT AND WATER CORROSION IN ELECTRICAL CONNECTORS. HIGH AMPERAGE ABS ELECTRICAL WIRES COULD SHORT- OUT AND CAUSE A FIRE; AN ENVIRONMENTAL, POLLUTION AND SAFETY ISSUE. *TR

NHTSA ID

10683723

Incident

Feb 19, 2014

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE REVERSING AT LOW SPEEDS, THERE WAS AN ABNORMAL NOISE AND THE ENGINE DETACHED FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BOLTS THAT SUPPORT THE TRAY FOR THE ENGINE AND THE FRAME WERE CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 144,000.

NHTSA ID

10664917

Incident

Dec 12, 2014

Mileage

144,000 mi

I WAS DRIVING THE VAN THIS AFTERNOON ON A PUBLIC ROAD WHEN FOR NO APPARENT REASON THE VAN STARTED SMOKING FROM UNDER THE ENGINE. I PULLED INTO A AUTOMOTIVE GARAGE AND GOT OUT OF THE VAN AND IT WAS STILL SMOKING BADLY. I INDIVIDUAL WHO ACTUALLY WORKED AT THE GARAGE WAS ON HIS WAY HOME FROM A RESTAURANT AND PULLED INTO THE PARKING AREA. HE HAD ME GO INTO THE VEHICLE TO PULL THE LATCH TO THE HOOD AND WHEN HE OPENED THE HOOD THE ENGINE AND OTHER PARTS WERE ENGULFED WITH FLAMES. THEY SPREAD INTO THE INSIDE OF THE VAN AND DESTROYED THE DASH BOARD, WINDSHIELD AND OTHER AREA. THE ROOF ON THE INSIDE WAS MELTING. THEY WERE ABLE TO PUT OUT THE FIRE BUT THE VAN IS DESTROYED. THE INDIVIDUAL WHO STOPPED AND HELPED ME OUT IS A MECHANIC AT THAT PARTICULAR GARAGE AND SAID IT LOOKED TO HIM LIKE A ELECTRICAL PROBLEM STARTED THE FIRE. I AM NOW WITHOUT A VEHICLE. PERSONAL ITEMS I HAD INSIDE THE VAN ARE RUINED OR DESTROYED. *TR

NHTSA ID

10614882

Incident

Jul 20, 2014

Mileage

166,000 mi

DRIVING HOME, DOWN COUNTRY HIGHWAY, VEHICLE HAD NO NOISE OR GAVE WARNING. HEARD A LOUD HISS/NOISE, SMOKE SCREEN APPEARED BEHIND VAN, I COASTED VAN OFF ROADWAY. HAD VEHICLE TOWED HOME. UPON CHECKING, ROD WENT THRU ENGINE AND TRANSMISSION CASING. AM WONDERING IF THIS HAS BEEN A PROBLEM WITH THIS VEHICLE, BECAUSE I HEARD OF A SIMILAR INCIDENT JUST TODAY WITH ANOTHER WINDSTAR. THANK YOU. *TR

NHTSA ID

10577725

Incident

Apr 17, 2013

WE BOUGHT OUR VAN IN MARCH 2012. BY APRIL 2012 WE BEGAN NOTICING PROBLEMS WITH SHIFTING. IT SHIFTS HARD. THE WINDOWS STOPPED WORKING IN MAY 2012. THE LIGHTS ON THE DASH FOR THE ABS AND BRAKES ARE ALWAYS ON. THE BRAKES ARE NOT VERY GOOD AND THE PEDAL MUST BE PUSHED HARD TO GET THE VAN TO STOP. OUR BIGGEST ISSUE IS WITH THE TRANSMISSION. THE MECHANIC AT AAMCO WOULD NOT EVEN CHANGE THE FLUID BECAUSE IF HE CHANGED THE FLUID THEN THE TRANSMISSION WOULDN'T BE ABLE TO SHIFT. I DON'T KNOW THE DETAILS BUT I DO KNOW THAT MY VAN IS NOT SAFE TO DRIVE. *TR

NHTSA ID

10523927

Incident

Apr 2, 2012

Mileage

97,000 mi

ABS LIGHT AND BRAKE LIGHT HAVE BEEN ON FOR MONTHS OFF AND ON. HAVE A SLIGHT BRAKE FLUID LEAK. WAS BACKING INTO MY DRIVEWAY AND THE O/D LIGHT CAME ON AND STARTED FLASHING, THE ODOMETER WENT BLANK, SPEEDOMETER STOPPED WORKING AND THE A/C BEGAN BLOWING HOT AIR. CHECKED FUSE #10 AND FOUND IT WAS BLOWN. REPLACED FUSE #10. ODOMETER AND SPEEDOMETER WORK BUT OTHER LIGHTS STILL ON. HAVE AN APPOINTMENT TO HAVE THE VAN LOOKED AT TOMORROW. *TR

NHTSA ID

10522419

Incident

Jun 25, 2013

Mileage

121,000 mi

ONGOING PROBLEM AS DESCRIBED IN TSB 04-17-4 & 03-16-1. THESE TSB'S TELL US THAT FORD MOTOR COMPANY WAS AWARE OF THIS DESIGN FLAW AND CONTINUED TO MANUFACTURE AND SELL DEFECTIVE VEHICLES. THE PROBLEM EXIST IN THEIR FAULTY 3.8L ENGINE AT THE INTAKE MANIFOLD. THE POOR DESIGN ALLOWS OIL TO SEEP INTO THE INTAKE PLENUM AND OVER TIME THE OIL ERODES AWAY THE RUBBER AROUND THE ISOLATOR BOLTS AND GASKETS. WHEN THIS HAPPENS THE ENGINE READS LEAN FUEL CODES ON BANKS 1& 2 AND A VACUUM LEAK. TO COMPENSATE FOR THESE LEAN CODES , MORE GASOLINE IS PUMPED INTO THE PLENUM CAUSING A RICH EXHAUST MIXTURE WHICH IS THEN SENT OUT THE TAIL PIPE INTO THE ATMOSPHERE. FORD MOTOR COMPANY DESIGNED AND BUILT THESE ENGINES AND THEY NEED TO BE HELD ACCOUNTABLE FOR CORRECTING THIS PROBLEM. REMEMBER, THIS IS AN ONGOING WIDESPREAD PROBLEM WITH TENS OF THOUSANDS OF THESE ENGINES FOULING UP THE AIR THAT WE BREATH EVERY DAY. *TR

NHTSA ID

10502719

Incident

Mar 17, 2011

Mileage

85,000 mi

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT WARNING LIGHT CONTINUED TO ILLUMINATE. THE VEHICLE WAS TAKEN TO THE DEALER SEVERAL TIMES, WHERE NUMEROUS ATTEMPTS WERE MADE TO CORRECT THE FAILURE. THE DEALER ALSO RESET THE COMPUTER SYSTEM BUT THE REMEDY ONLY LASTED FOR APPROXIMATELY THREE MONTHS BEFORE RECURRING. THE MANUFACTURER WAS NOTIFIED AND STATED THAT THERE WAS NO RECALL FOR THE VEHICLE AND THAT THEY COULD NOT ASSIST. THE FAILURE MILEAGE WAS 69,000.

NHTSA ID

10499534

Incident

Dec 3, 2012

Mileage

69,000 mi

THE 1ST PROBLEM, HAD A CHECK ENGINE LIGHT ON MY 2001 FORD WINDSTAR, C1518 "INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN." AFTER READING FORUMS, MOST POINTED TO A PLASTIC "BUSHING" CLIP COMING OFF LEAVING A CONTROL ARM 2ND PROBLEM, ABS CHK LIGHT AND BRK CHK LIGHT COME ON AFTER DRIVING FOR A FEW MINUTES, ABS MODULE AND ABS SENSOR WENT OUT. *TR

NHTSA ID

10487803

Incident

Aug 3, 2011

THE ANTILOCK BRAKE SYSTEM LIGHT AS WELL AS THE TRACTION CONTROL LIGHTS KEEP COMING ON. GARAGE CAN'T TELL THE EXACT CAUSE. THE BOOSTER ARM BUSTED, KEEPING THE BRAKES ENGAGED AS DRIVEN. THE BOOSTER ARM WAS REPLACED AND THE LIGHTS ARE STILL ON. I RESET IT, AND THEY REAPPEAR AFTER A SHORT TIME. I NOW SMELL THE BRAKES WHEN APPLIED. I'VE HAD ENGINE REPLACED AT 101,000 MILES, TWO TRANSMISSIONS, MULTIPLE BRAKE JOBS, REAR AXLE REPAIRED, FRONT AXLE REPAIRED, FRONT TIE RODS REPAIRED. THE ALIGNMENT ON MY VEHICLE COULD ONLY BE PARTIALLY COMPLETED.... TOE, AND ANOTHER ALIGNMENT DONE, BUT THE COMPLETE ALIGNMENT WOULD NEED A HOLE DRILLED IN THE FRAME AND A BOLT MOVED OVER - BAD DESIGN BY FORD. I'VE ALSO HAD TO HAVE THE OXYGEN SENSOR REPLACED AT MY OWN EXPENSE. THE VEHICLE IS A TICKING TIME BOMB, PIECE OF CRAP. *TR

NHTSA ID

10475079

Incident

Sep 1, 2011

AS I PUT THE HEAT, DEFROSTER, OR AIR CONDITIONING ON, IT JERKS ALOT AND WHEN I STOP AT A RED LIGHT OR STOP SIGN IT STALLS. I HAVE TO PUT MY 4 WAYS ON, SHUT THE VAN OFF, AND RESTART IT WITHOUT THE HEAT OR AIR ON. I FEEL THIS IS A VERY DRASTIC SAFETY ISSUE DUE TO THE FACT IF I'M DRIVING ON A HIGHWAY AND I STOP AT A RED LIGHT AND IT STALLS, IF THERE IS TRAFFIC BEHIND ME COMING RAPIDLY I CAN BE REAR ENDED AND CAUSE AN ACCIDENT. THIS HAS HAPPENED TO ME IN THE NOVEMBER INCIDENT. LUCKILY THE LIGHT WAS STILL RED. *JS

NHTSA ID

10462368

Incident

Nov 21, 2011

Mileage

41,200 mi

ABS LIGHT IS CONTINUALLY ON EVEN THOUGH THE BRAKES HAVE BEEN REPAIRED MULTIPLE TIMES, BRAKE LIGHT IS CONTINUALLY ON EVEN THOUGH THEY HAVE BEEN REPAIRED MULTIPLE TIMES, BRAKING TIME HAS INCREASED AS IF THEY BREAKS DO NOT ALWAYS IMMEDIATELY WORK, BRAKES TURN ON SQUEEL WITHOUT WARNING, BURNING SMELL. I AM ABOUT TO TAKE THE VAN IN AGAIN. I THINK THE BRAKE FLUID IS NOW LEAKING AND DAMAGING THE ENGINE. *TR

NHTSA ID

10447146

Incident

Jun 15, 2010

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT WAS DRIVING APPROXIMATELY 50-55 MPH WHEN A LOUD NOISE WAS HEARD FROM THE VEHICLE. THE CONTACT STATED THAT IT SOUNDED AS IF SOMETHING HAD FALLEN FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY ADVISED HER THAT THE SPARK PLUGS WERE INVERTED IN THE ENGINE AND THE HEAD GASKET NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED A 5 PERCENT DISCOUNT TO THE CONTACT IF THE VEHICLE WERE TO BE REPAIRED AT AN AUTHORIZED DEALER. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGES WERE APPROXIMATELY 120,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10440588

Incident

Dec 17, 2011

Mileage

120,000 mi

2002 FORD WINDSTAR MINI VAN. CONSUMER STATES AFTER FILLING UP THE TANK AND TURNING ON THE IGNITION, FLAMES FLEW UP AND AFTER PUTTING WATER ON IT THERE WAS A FLASH FIRE AND EXPLOSION *TGW

NHTSA ID

10403444

Incident

May 2, 2011

CHECK ENGINE LIGHT ON - 2002 FORD WINDSTAR - SEEMS TO BE COMMON COMPLAINT ONLINE SERVICE BULLETIN ISSUED IN 2003 - DIAGNOSTICS SAYS IT'S THE O2 SENSOR, THIS IS NOT THE CASE VEHICLE IDLES ERRATICALLY AT STOPS - SOME HESITATION - NOW HESITATES AND RUNS BAD IN RAIN I'VE REPLACED THE TRANSMISSION TWICE - ENGINE ONCE - CRAPPY VEHICLE. *TR

NHTSA ID

10402050

Incident

Apr 1, 2011

Mileage

50,000 mi

2002 FORD WINDSTAR LX. CONSUMER STATES PROBLEM WITH BRAKE SYSTEM *TGW THE CONSUMER STATED THE FRONT WHEEL BEARINGS, ENGINE GASKET AND FUEL INJECTOR NEEDED TO BE REPLACED. THE ABS LIGHT ILLUMINATED. *JB

NHTSA ID

10372791

Incident

Dec 1, 2010

ABS BRAKE LIGHT COMES ON WHEN THE CAR GETS HOT. WHEN THE CAR IS COLD THERE IS NO PROBLEM WITH THE ABS SYSTEM. THE AIR BAG LIGHT CAME ON AT ABOUT 75,000 MILES, COST TO REPLACE CIRCUIT BOARD 675 DOLLARS. THE ENGINE INTAKE MANIFOLD WARPED WHICH TURNED ON THE ENGINE REPAIR LIGHT, COST 950 DOLLARS TO REPAIR. UPDATED 01/20/11 *BF

NHTSA ID

10368838

Incident

Oct 1, 2010

Mileage

80,000 mi

1. THE CAR STOPS ANY TIME WHILE DRIVING 2. THAT HAPPENS BETWEEN 2 AND 5 TIMES A WEEK 3. WHEN THAT HAPPENS, I PUT THE CAR IN PARK THEN RESTART IT. I TOOK THE CAR TO MULLIMAX FORD DEALER IN APOPKA, FL SEVERAL TIMES. I PAID FOR DIAGNOSTICS, THEY CANNOT FIND THE REASON OR THE PROBLEM. THEY USUALLY PERFORM NECESSARY REPAIRS, BUT THE PROBLEM IS STILL NOT SOLVED. RECENTLY I WAS MAKING A LEFT TURN WHEN THE CAR DIED. SEVERAL MOTORIST STEPPED ON THEIR BRAKE TO AVOID STRIKING MY VEHICLE. THE PROBLEM WAS ON INITIAL STAGE, WHEN THE VEHICLE WAS REPAIRED FOR ANOTHER RECALL ON 11-25-09. *TR

NHTSA ID

10332473

Incident

Jan 15, 2010

Mileage

118,000 mi

ACTS LIKE DYING BUT SURGES FORWARD WITH BRAKE ON. *TR

NHTSA ID

10320335

Incident

Mar 15, 2010

Mileage

90,500 mi

SUDDEN ACCELERATION AT A STOP LIGHT ON 2 OCC. *TR

NHTSA ID

10314828

Incident

Jul 15, 2009

Mileage

90,000 mi

TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. WHILE DRIVING THE VEHICLE WOULD STALL WITHOUT ANY PRIOR WARNINGS. THE VEHICLE WAS TOWED TO A DEALER TWICE. THE TECHNICIANS WERE ABLE TO RESTART THE VEHICLE, BUT WERE UNABLE TO DETERMINE THE CAUSE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 35,000. THE CURRENT MILEAGE WAS APPROXIMATELY 75,000. UPDATED 12/22/09 *BF UPDATED 12/22/09

NHTSA ID

10292987

Incident

Nov 21, 2007

Mileage

35,000 mi