2002 Ford Windstar Problems: 5 Known Issues

2002 Ford Windstar Problems: 5 Known Issues | Au7o

NHTSA Recalls22 recalls

SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

Ford Motor Company (Ford) is recalling certain model year 1998-2003 Windstar vehicles manufactured September 2, 1997, to July 3, 2003. The affected vehicles were previously remedied to safeguard against the rear axle cracking from corrosion, however, the remedy brackets may have been misinstalled. The incorrect bracket installations may limit the effectiveness of the service repair for NHTSA recalls 10V-385, 12V-193, and 12V-195.

Campaign #15V60800029/09/2015

POWER TRAIN:AXLE ASSEMBLY

FORD IS RECALLING CERTAIN MODEL YEAR 1998-2003 WINDSTAR VEHICLES MANUFACTURED FROM SEPTEMBER 1, 1997, THROUGH JULY 3, 2003, AND CURRENTLY REGISTERED OR ORIGINALLY SOLD IN VIRGINIA. OVER TIME, CORROSION CAN WEAKEN THE REAR AXLE MAKING IT SUSCEPTIBLE TO TORSIONAL STRESS. CORROSION AND STRESS CAN LEAD TO CRACKS WHICH, IF UNDETECTED, CAN INCREASE AND RESULT IN A COMPLETE FRACTURE OF THE AXLE.

Campaign #12V19300003/05/2012

SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

FORD IS RECALLING CERTAIN MODEL YEAR 1998-2003 WINDSTAR VEHICLES MANUFACTURED FROM SEPTEMBER 1, 1997, THROUGH JULY 3, 2003, REGISTERED IN PUERTO RICO. DUE TO INCREASED STRESSES CAUSED BY HIGH CYCLES OF TORSIONAL LOADING, SPECIFIC TO THIS MARKET, THE REAR AXLE CAN CRACK.

Campaign #12V19500003/05/2012

SUSPENSION:FRONT:CONTROL ARM

FORD IS RECALLING CERTAIN MODEL YEAR 1999-2003 WINDSTAR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATE OF VIRGINIA. CORROSION-RELATED FRACTURES OF THE FRONT LOWER CONTROL ARM REAR ATTACHING BRACKETS AND BODY MOUNT ATTACHMENTS MAY OCCUR.

Campaign #12V19400003/05/2012

STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS

FORD IS RECALLING CERTAIN MODEL YEAR 1999-2003 WINDSTAR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, UTAH, VERMONT, WEST VIRGINIA, AND WISCONSIN. A SEPARATION OF A FRONT LOWER CONTROL ARM REAR ATTACHING BRACKET MAY RESULT IN A LOWER CONTROL ARM SEPARATION. A SEPARATION OF BOTH FRONT SUBFRAME REAR BODY MOUNTS MAY RESULT IN SEPARATION OF THE STEERING INTERMEDIATE SHAFT.

Campaign #11V03000026/01/2011

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Frequently Asked Questions

What are the most common Ford Windstar problems?

According to Au7o's analysis of 4,500+ owner reports, the 2002 Ford Windstar has 5 documented issues. The most frequently reported are: AX4S/AX4N Automatic Transmission Failure, Intake Manifold Gasket Coolant Leak, 3.8L V6 Head Gasket Failure. Of these, 4 are rated critical and should be addressed promptly.

Is the Ford Windstar reliable?

The 2002 Ford Windstar has 5 known issues documented across 4,500+ owner reports. 4 issues are rated critical: AX4S/AX4N Automatic Transmission Failure and Intake Manifold Gasket Coolant Leak and 3.8L V6 Head Gasket Failure and Rear Axle Breakage (Safety Recall). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Windstar problems?

Repair costs for known Ford Windstar issues range from $100 to $3,100, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, AX4S/AX4N Automatic Transmission Failure, typically costs $400-$3,100 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1996-2003 Ford Windstar AX4S/AX4N Automatic Transmission Failure?

The Ford Windstar equipped with the AX4S (1995-2000) and AX4N/4F50N (2001-2003) automatic transmissions suffers from widespread premature transmission failure. CarComplaints.com records 140 complaints for the 2000 model year alone, and 166 problems for the 2003 model year, making… Repairs typically run $400-$3,100. Severity: high.

What is the 1999-2003 Ford Windstar Intake Manifold Gasket Coolant Leak?

The 3.8L V6 intake manifold gaskets degrade and allow coolant to leak externally or internally into the engine oil. This is closely related to the head gasket issue and can lead to overheating and engine damage if not addressed. Repairs typically run $400-$900. Severity: high.

What is the 1999-2003 Ford Windstar 3.8L V6 Head Gasket Failure?

The 3.8L Essex V6 in the Windstar is notorious for head gasket failure, often caused by the aluminum heads warping from overheating. The composite head gaskets deteriorate and allow coolant into combustion chambers. Repairs typically run $1,500-$3,000. Severity: high.

What is the 1998-2003 Ford Windstar Rear Axle Breakage (Safety Recall)?

The Windstar rear axle is prone to stress fracture and complete breakage at the spring perch, causing the wheel to tuck under the vehicle. This was subject to NHTSA recall 10V-040. Rust and corrosion in northern climates accelerates the failure. Repairs typically run $800-$2,000. Severity: high.

What is the 1995-2003 Ford Windstar Power Window Motor and Regulator Failure?

Power window motors and regulators fail frequently, especially on the driver's side. The plastic guide clips break, causing the window to drop into the door or operate very slowly. Repairs typically run $100-$300. Severity: low.

2002 Ford Windstar Problems: 5 Known Issues

All 5 Known Issues

1999-2003 Ford Windstar: Intake Manifold Gasket Coolant Leak#

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1999-2003 Ford Windstar: 3.8L V6 Head Gasket Failure#

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1996-2003 Ford Windstar: AX4S/AX4N Automatic Transmission Failure#

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1998-2003 Ford Windstar: Rear Axle Breakage (Safety Recall)#

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1995-2003 Ford Windstar: Power Window Motor and Regulator Failure#

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Other Ford Models

Frequently Asked Questions

What are the most common Ford Windstar problems?

Is the Ford Windstar reliable?

How much does it cost to fix common Ford Windstar problems?

What is the 1996-2003 Ford Windstar AX4S/AX4N Automatic Transmission Failure?

What is the 1999-2003 Ford Windstar Intake Manifold Gasket Coolant Leak?

What is the 1999-2003 Ford Windstar 3.8L V6 Head Gasket Failure?

What is the 1998-2003 Ford Windstar Rear Axle Breakage (Safety Recall)?

What is the 1995-2003 Ford Windstar Power Window Motor and Regulator Failure?