- NHTSA has opened an investigation into complaints of broken rear axles on 1999-2003 Ford Windstar minivans.
- Fracture of a rear suspension axle could result in a loss of vehicle control.
- The agency said it has 234 complaints alleging rear axle failure in the minivans.
WASHINGTON — An estimated 900,000 Ford Windstar minivans from the 1999-2003 model years are being investigated by the National Highway Traffic Safety Administration for broken rear axles.
"Fracture of a rear suspension axle could result in loss of vehicle control," said NHTSA in documentation explaining the problem. The agency said it has 234 complaints alleging rear axle failure in the minivans, including two that resulted in minor crashes. There have been no injuries or fatalities linked to the suspension concerns.
The action, called a preliminary evaluation, is sometimes a precursor to a recall.
"Over half the complaints [128] allege a complete fracture of the axle beam," said NHTSA in its defect investigations summary. "Fifty-six complaints indicate that the axle failure occurred at speeds of 40 miles per hour or greater. One crash occurred while the vehicle was traveling on a highway. The rear axle reportedly 'snapped in half' after the vehicle struck a pothole."
NHTSA said the problem seems to be worse in so-called "Salt Belt" states. "The rear axle beam in the subject vehicles is an inverted 'U' channel design, which appears to provide a collection point for road salt slurry, resulting in corrosion that progressively weakens the part until it fractures," it said.
An unidentified consumer posted the following complaint about the Windstar on the NHTSA site on May 15, 2010. "The van started pulling and swerving like I had flat tires. The van has 124,210 miles [on the odometer] and has been diagnosed with a broken rear axle. Estimated repair cost is $900."
The federal investigation into the Windstar comes as the U.S. Congress is zeroing in on auto safety issues following record recalls by Toyota.
The U.S. Senate Committee on Commerce, Science and Transportation is scheduled to hold a hearing at 2:30 p.m. EDT on Wednesday to discuss new auto safety legislation dubbed "The Motor Vehicle Safety Act of 2010" and drafted in response to Toyota's handling of its massive recalls. The House Energy and Commerce Committee will hold a hearing entitled "update on Toyota and NHTSA's response to the problem of sudden unintended acceleration" at 10 a.m. EDT on Thursday, May 20.
The Senate bill is similar to a measure now being considered by the House of Representatives. Both would set standards for pedal placement and keyless ignition systems. The proposed legislation would also require all new cars and light trucks to be equipped with event data recorders and brake override systems.
Inside Line says: If you own the aforementioned Windstar, be aware that the federal government is looking into complaints of the fracture of the rear suspension axle. Also, be aware that major congressional hearings are on tap this week regarding auto safety. — Anita Lienert, Correspondent
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reowen says:
06:03 AM, 06/17/2011
We finally got the van back yesterday after sitting at the dealer since Nov. 19, 2010. They gave us a Kia minivan from Enterprise to use for the past 6 months. The dealer charged Ford for a new battery, but when they went to start the car it was dead. The old battery was still in the car. I brought this to the service desk's attention. They changed the battery. I think they were screwing Ford.
I looked under the car to see if they did the repairs and from what I can tell they did. But now the car squeaks like crazy due to sitting for so long, the wheel bearings sound like crap and there is more body rust as they had my van just sitting in a gravel weed stewn unlocked yard. The dealer told me it was go to be stored in a locked yard when we had to leave it and it was only going to be till Jan 2011.
The steering wheel is no longer in the correct position so I suspect they failed to re-align the wheels after all the chasis work.
I wish they had offered be $10K for it.
From what Ford spent on the work, the rental, etc it would have cost them less money.
I do not blame Ford, in fact I think they tried to do what was right. In 20/20 hindsight it would have been better if they had offered owner's the buy out, a new car at cost and 0% financing for 5 years.
I am sure this is going to be a big hit on them
Thanks
2001 Ford Windstar with 151 K miles
mike549 says:
12:21 PM, 01/05/2011
I beg to differ with the Feds on the issue of no fatalities with these axle beams breaking, a father of two children in Whitman Massachusetts was killed when the beam broke and he lost control of the vehicle. Shortly before Christmas another man was killed in Rhode Island reported by the Providence Journal. What worries me the most are all the Windstars I see in Massachusetts that are riding around with serious rot in the rocker panels that I know people have not taken in for the checkup of the I-Beam. Maybe they didn't get a notice in the mail. This danger is as serious as the Camry accelerator problem. The national media needs to pick this up. Windstars have just as serious problem with the right front lower A-Frame mount, because the A/C Condesation tube drains water right on top of the rear mount to the front subframe and the condenastion causes this mount to rot off the frame. One of my workers was driving a 2000 Windstar when this mount broke, the A-Frame came away the vehicle, the vehicle carrened off the road and nearly hit a tree. If you own a Windstar and it is not at the Dealer awaiting an I-Beam then get a flashlight and check this mount. If you google this situation you will see how many others had this problem. I notified Ford by letter with no response.
nowindstar says:
01:13 PM, 10/23/2010
I had a 2002 Windstar in which the rear axle was badly cracked and almost all the way thru The car would badly sway on the road. This was in June. When I complained to Ford they never said there was a problem with the Windstars that were manufactured from 1998-2003. Since the car was over 8 years old with 148,000 miles I donated the car and bought a Subaru since the price they quoted was $1450 and there were no new rear axles available at the time and I would have to get one from a salvage yard and I did not want to do that. I would have gladly kept the car if I knew they would have repaired them free of charge and given me a free rental in the meantime. I am really mad at Ford since they knew of the problem in June and never said anything about it. I did not find out anything til now and I got the recall in the mail. Ford will get my complaint
fsberlin says:
08:32 AM, 10/19/2010
I have a 2002 Windstar. But I live in Kansas which is not included in the recall. The rear axle broke completely in two while traveling on the interstate. Luckily the complete break occured at a rest stop/service station and I had just stopped to see why the van was driving so poorly. I had just put in 950 miles of traveling that day & was 50 miles from home. But my repairs were much more, because the Ford repairshop found rusted out e-brake cables, tie rods, etc,, too...over $2700, what with alignment,etc. And the van had less than 72,000 miles on it.
whatsupford1 says:
05:21 PM, 10/14/2010
I am the owner of a 1999 Ford Windstar and my rear axel cracked completely in half while driving on the exspresway. My car went across two lanes of traffic and hit an overpass wall, and I got hurt. There IS A RECALL on these Vans, People are getting hurt, and Ford is DOING NOTHING about it besides sending out paperwork for you to fill out if you complain. The recall was in NEWSDAY on Long Island 2 monthes ago, and all owners were to receive this notice in September 2010, I have not received mine, have any of you?????
They should be accountable for ALL damages AND injuries!!! And they are not even polite when yo finally get through to them, like you did something wrong!!
They need to come forward and reimbuse All of the people who have clearly been put at risk of injury, and have paid out for hefty repairs due to their FAULY REAR AXELS...
deadstar says:
05:59 AM, 08/28/2010
Spent $868 to replace this on my 2001.
Ford will get the bill from 7-13-09
It's about time. My mechanic replaced 4 before this.
Own a Chrysler T&C now.
jillianh says:
06:40 AM, 08/23/2010
I have a 2001 Windstar with 96,000 miles on it & the rear support/track bar (axle beam) is almost split in 1/2. Both rear tires are splayed out-at the bottom. I'm getting nowhere with Ford or the dealerships. If enough insurance companies cover the tow for this problem, maybe they can get on Ford to issue compensation or something?!
iluvmyvan says:
05:47 PM, 08/12/2010
I have a 2001 Windstar with 85,758 miles on it. I just had it in to a dealership for noise in the front end.
They found that both front links are loose and replaced both of them. I was told the rear axle is broken half way around and unsafe to drive. I was told by the service writer and service manager that they have seen two other vans with the same problem. I called Ford to ask if there was a recall or a tsb on this. I was told by two diffrent people there was nothing on this and that they have never heard about this problem.
According to the NY Times article dated May 5, 2010 it is written:
Most of the axle failures occurred after 100,000 to 150,000 miles, well beyond the factory warranty, said a Ford spokesman. Well as you can tell this is not always the case.
The estimates to fix the van run from $800 at an independent garage to over $1200 at the local Ford dealer. Neither Ford or the dealership will take responsibility for this damage and we are left to foot the bill for repairs on our own.
It is imperative that Ford issue a recall on this problem before some innocent person is severly hurt or even worse loses their life due to this dangerous situation.
Signed: iluvmyvan
taximom101 says:
05:41 PM, 07/10/2010
I have a 2002 windstar. while I was driving down the road at about 40 mph, I felt like I lost control of the back end of the car much like when you hit a patch of ice. I then started to hear metal scrapping noises. when I pulled over I saw that my rear passenger tire was tilted in and the rear axle was cracked! this just happend last week. scary! I had my kids in the car at the time.
vbc711 says:
07:19 PM, 06/07/2010
.026 percent have been reported. I just had my mechanic check mine. It is indeed cracked almost completely through. It will not pass inspection. I cannot drive it. I did report it to the NHTSA. I received an immediate response from a live person requesting additional information and photos - which I sent. So anybody reading this - whether you repaired it or not....please report it to the NHTSA. They are very interested in this and taking it seriously. In a NY Times article dated May 5, 2010 it is written:
Most of the axle failures occurred after 100,000 to 150,000 miles, well beyond the factory warranty, said a Ford spokesman, Said Deep. He said there was no safety problem because "the operator retains control of the vehicle at all times" and "the few reports alleging loss of control are inconsistent with how Ford would expect these front-wheel-drive vehicles to respond."
"David Champion, the director of the auto test center for Consumer Reports magazine, said his review of some owner complaints found no reports of crashes, but he considers the rear axle breaking to be "a dangerous event" and "Ford is running a fine line if they do not consider this to be a safety defect."
Under federal law, an automaker that knows of a safety defect must report it to the agency. But often the agency learns of problems through consumer complaints. These can be filed by telephone, mail or through the N.H.T.S.A. Web site."
How concerned and kind of the Ford spokeperson. I advise you all to report this whether you have fixed it or not. By the way when I called customer service at Ford Motor Company - the rep said she had never heard about it an suggested I take my van to a Ford dealer. UmmmHmmm - yeppers- I'll drive 20 miles with a cracked axle. Great advice from the superstar at Ford. And yes I do have her name and emplyee ID number.