The 1995 Ford Windstar has 8 recalls, the most serious being multiple fire risks: a loose alternator output wire that can overheat at its connection point, and a wiring harness that can wear through against a brace behind the dashboard, either of which can start an underhood fire.
Fuel and brake integrity round out the more serious concerns. In hot-weather states across the South and Southwest, the standard 20-gallon fuel tank can develop cracks near the front mounting strap and leak fuel. On the brake side, a crossover brake line that runs above the catalytic converter can corrode where it contacts a moisture-absorbing insulator, with exhaust heat speeding up the process until the line develops a leak. A separate brake line concern affects vehicles registered in northern and mid-Atlantic states where road salt is common: the brake lines in those vehicles can corrode to the point of leaking fluid, which triggers the brake warning light and can extend stopping distances enough to raise crash risk.
There are also two chassis-level concerns. The front coil springs can fracture due to corrosion, and a broken spring coil can contact the tire and cause a flat. This issue affects Windstars from the 1995 through 1998 model years, so some of these vehicles may already carry prior repair history from the later campaign covering the same defect on 1997 and 1998 models. If an earlier repair was performed on a 1997 or 1998 vehicle, it may or may not have addressed this underlying spring corrosion concern on the specific unit in question.
At a glance
What can fail
The brake line above the catalytic converter may touch the dashboard insulator. Salt and water in the insulator cause corrosion, worsened by exhaust heat, potentially creating a brake line leak.
What the fix does
Your dealer will reposition or replace the brake line as needed.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
Some brake lines were twisted during assembly and rub against the dash panel insulator above the catalytic converter. This rubbing wears away the line's corrosion protection, allowing salt and water to cause rust that can eventually crack the brake line and cause leaks.
What the fix does
Dealers will inspect the brake line for corrosion and clearance. Uncorroded lines are repositioned. Corroded or leaking lines are replaced with a nylon-coated line and secured with three retaining clips.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The front coil springs can fracture due to corrosion over time.
What the fix does
Ford will replace both front coil springs at no charge if either fractures within 10 years of the warranty start date, with unlimited mileage coverage that transfers to subsequent owners.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The fuel tank can develop cracks in the forward strap area due to extreme heat in certain hot-weather states. This affects the standard 20-gallon tank.
What the fix does
Dealers will install a reinforcing brace at the strap bolt hole and replace the tank strap with a longer one. If a leak is found from a crack, the tank will be replaced along with a spacer and longer strap.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
A brace running from the instrument panel to the cowl may rub against and damage insulation on a nearby wire harness, potentially causing an electrical short and fire.
What the fix does
A shield will be installed on the brace, and protective convolute material will be added to the adjacent wire harness.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The wire connecting the alternator to the power distribution box may be loose. A loose connection can overheat due to electrical resistance and potentially cause an underhood fire.
What the fix does
The connection will be inspected and tightened. If the power distribution box housing is damaged, the entire underhood wiring harness will be replaced.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The wiring harness insulation can wear away where it contacts a brace running from the instrument panel to the cowl, potentially exposing the wires.
What the fix does
Dealers will install a protective shield on the brace and wrap convolute material around the adjacent harness.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The wire from the alternator wasn't connected tightly to the power distribution box, which could cause a loose electrical connection.
What the fix does
Dealers will inspect and tighten the connection. If the power distribution box housing is damaged, they'll replace the underhood harness and box.
Summarized — see the official notice for exact wording, dates, and contacts.
