Ford Windstar Recalls

The Ford Windstar has 47 recalls spanning the 1995–2003 production run, with the most serious being a rear axle corrosion defect on 1998–2003 models where the axle can crack and fracture completely, causing sudden loss of vehicle control.

The rear axle issue is the most persistent problem across the Windstar's later production years. On 1998–2003 vehicles registered in salt-belt states, Virginia, and Puerto Rico, road salt and torsional stress can weaken and fracture the rear axle, making the vehicle difficult or impossible to control. An earlier repair campaign for this defect involved reinforcement brackets that were sometimes misinstalled, meaning some 1998–2003 vehicles that went through the prior repair may still be at risk. A related corrosion issue on 1999–2003 models affects the front lower control arm mounting brackets in certain states, where bracket separation can cause the front control arm to detach and reduce steering control.

Fire risk appears across several model years. On 1997 models equipped with the AX4S automatic transmission, a servo cover can separate while driving, spraying transmission fluid onto the catalytic converter and starting a fire. On 1999 models with auxiliary rear air conditioning, a stalled blower motor can overheat its resistor and catch fire. On 1995 models, a wiring harness can abrade against an instrument panel brace and short-circuit, and a loose alternator output wire connection can overheat and ignite an underhood fire. Also on 1995 models registered in hot-weather states, the 20-gallon fuel tank can develop cracks that leak fuel, and a brake line routed above the catalytic converter can corrode and leak, extending stopping distances.

On 2001 models, the floor mat on vehicles with the adjustable pedal option can catch the accelerator pedal and stick the throttle open; the same issue affects certain 2000 models. The 2001 model year also has second- and third-row seat-to-floor latches that can release under load in a crash, and a restraint control module or crash sensor that may be missing mounting screws, potentially affecting airbag and seatbelt performance. The 2003 model has a similar seat latch issue where second- and third-row bench seat floor latches can release in a crash.

On 2000 models, the windshield and liftgate glass was bonded with incorrect urethane, creating a weaker adhesive bond that can deteriorate and reduce glass retention in a crash. There is also a fuel line connection on 2000 models that can pull apart in a crash and leak fuel. The 1999 model year has a wiper motor that can allow water and salt intrusion, causing the intermittent wiper switch to malfunction or overheat, and a 1999 subframe that may have received inadequate corrosion coating during production.

Going further back, 1998 models with the optional integrated child seat have a headrest lockout that may not hold the headrest down when the child seat is deployed, reducing head protection for a child in a crash. The 1997 and 1995–1998 model years are subject to front coil spring corrosion in salt-belt regions, where a fractured spring can contact and deflate a front tire. On 1996 models, driver seat mounting fasteners may not have been tightened to specification, meaning the seat can shift or break free in a crash. That same year also saw incorrect replacement brake rotors installed during service that can eventually cause wheel stu