2002 Ford Windstar: ball joint or control arm failure

Filed May 23, 2018 · Suspension · 168,000 miles · KY

Ford rear axle recall. Received a recall letter for an inspection of the rear axle , which failed. The dealer found another recall about a front control arm, which they fixed. The rear axle was at my expense. The axle had the brackets installed, but improperly. I was told that the car was unsafe to drive, that the axle could break at any time. I'm on disability and can't afford to replace an axle that should be replaced by ford. I also can't afford to buy another vehicle! I have to drive regardless of this issue!

Filed Mar 5, 2018 · Body, Steering · WI

Rh back side of subframe, is rotted/corroded so bad that the metal tore all around the subframe bushing. To where it is not being held up by the bushing on the right hand lower/back is not holding up the front subframe... Now, the vehicle is making a very loud popping noise when driving and turning... And when turning fast enough (more turning left then right) can feel whole front end jerk like its about to go the opposite way the van...replaced the left front strut assembly and control arm to find out that did not solve the problem. Then after repairs and looking deeper.. Noticed right front side, sagging almost 2-4 inches lower then left front... That's when we noticed the subframe completely broken/rusted off from the body bushing (on the front right lower/rear bushing)

Filed Oct 14, 2015 · Steering, Suspension · 39,700 miles · WI

Complete deteriation of the front left and right sub frame attaching to the lower control arm attachments at the rear of subframe holding the rack and pinion assembly. This steel is flaking and appears to have laminte separations (looks like flakey pie crust). Cannot get a mechanic to replace leaking rack and pinion assembly due to the poor condition that will leave no material when it breaks off.

Filed Jan 9, 2015 · Body, Suspension · 154,000 miles · MA

When bringing my windstar in for an alignment it was found that the subframe had rotted and cracked near the control arm. Ford had "completed" the necessary repairs to address this issue and has stated that they are not responsible for the damage to the vehicle even though it was the original reason for the recall. According to the information from the original recall ford was supposed to replace the subframe however small brackets were added to the van instead. I do not feel that the recall was properly done by ford.

Filed Jun 9, 2014 · Brakes, Steering · 119,000 miles · MD · crash

I lost control on the highway I was driving I hit a pothole and my car when its own way I was coming home from the hospital from just giving birth two day earlier and I kept hearing a weird noise so I took my car to the shop and they said it was the lower control arm.

Filed Sep 12, 2013 · Steering, Transmission · DC

Van won't go into gear or drive . I don't know if it the corrosion fractures of front lower control arm or transmission . Trying to find out if any recalls would be on the van on what's going on with it .

Filed Sep 3, 2013 · Suspension · 130,000 miles · IN

My parents had recall 11s16 performed on their windstar on march 20th 2012. A vibration had been felt since jan of 2013. They had new tires installed and balanced. Problem persisted. I removed both front rims and inspected suspension. Passenger side lower control arm nut missing from bolt. Grade 10.9 metric bolt loose and partially backed out, unbelievably, washer still sitting on frame. Inspected drivers side of vehicle and problem becomes apparent. Multiple washers are stacked under head of bolt and under nut making full thread engagement impossible. Multiple phone calls to ford and dealership. The dealership is adamant that instructions stipulate "multiple shims" must be used, "up to six depending". A "gauge" is used during the install process. I request a copy of installation instructions but dealership says they don't have any. I request the same from corporate ford but they don't have any??!!?? How does ford perform the repairs from "instructions stipulating" and use "up to six shims" and then "gauge" if they do not possess instructions??!!?? Possible fixes: remove washer from under the head of the bolt but still use the one under the nut, use a lower height nut, use a longer bolt. All possible fixes make the repair much safer. Ford refuses all suggestions and puts my family back on the road and at risk. Multiple photos of properly repaired control arm kits are on the internet and all show proper thread engagement of the nut on the bolt. To keep my family safe should I do the repairs myself or do I put myself at legal risk?

Filed Feb 27, 2013 · Suspension · 74,000 miles · KY

Tl* the contact owns a 2002 ford windstar. The contact stated that while driving 5 MPH, the front passenger side wheel became detached from the vehicle. The vehicle was towed to an independent mechanic for diagnosis and the contact was informed that the bolt that connects the lower control arm to the front end cradle had become rusted. The contact was informed of the federal safety agency campaign number: 12v194000 (suspension). The dealer was notified and stated that the recall repair had already been done two years prior. The manufacturer was notified but offered no assistance. The vehicle had not been repaired. The failure and current mileage was 74,000. Updated 04/09/13*lj the consumer stated ford motor company, did not repair the vehicle the correct way. The consumer stated the vehicle fixed the vehicle in a cheap and quick manner. The consumer believed the front end and lower control arm should have been replaced, instead of adding brackets. The left front wheel was not connected to the vehicle. The consumer was informed the front end cradle was completely rusted through and should have been replaced.

Filed Dec 9, 2012 · Brakes, Engine · KY

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.

Filed Sep 21, 2012 · Suspension · IL

Tl* the contact owns a 2002 ford windstar. The contact stated that the vehicle was included in the federal safety agency campaign id number: 12v194000 (suspension:front:control arm) and was repaired. After the repairs, the contact noticed a clunking noise exhibited from the vehicle while driving. The vehicle was taken to an independent mechanic for diagnostic testing. The mechanic stated that there was water dripping from the air conditioner line where the original corrosion occurred on the sub frame, which corroded the component that was added under the recall. The vehicle was taken to the dealer where the technician then advised that the sub frame would have to be replaced. The vehicle was not further repaired. The approximate failure mileage was unknown.

Filed Sep 11, 2012 · Brakes, Engine · MD

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.

Filed Jul 25, 2012 · Brakes, Electrical · 150,000 miles · NJ

At times when is col,d the ABS and brake light is off while driving, when it gets hot the ABS and brake light turns on and the ABS fails to work. Code c1185 ABS power relay output circuit failure. I got to a stop sign and the road was wet and the van skidded , the ABS did not work. No one was hurt and I have seen all the complaints that ford owners are having. I don't know if my 2002 ford windstar had all the other recalls done, like the brake pressure differential deactivation switch (scds) and the rear frame welds that are breaking up on the chassis of many ford owners. I would like to verify what has been done to my ford windstar that I bought two months ago. I just had the inner and outer tie rod ends done along with the sway bar links at the front suspension.