Gamecockinnc

Hi-

Found you all in a google search and I need help quickly! I live in NC, married to a Marine so having to take car of car problems myself which is not good for some women in the south.

I have a Ford 2002 Windstar SEL. It has 29,700 miles on it. It is almost 2 years old.

In March I drove to see my parents in SC. It was a 140 miles drive. For a few days before the drive I had noticed a thump noise and whining noise when I turned the van. I have noticed the van pulls to the right for a long time but thought it needed to be aligned.

Got within 10 miles of my parents house and my van started making awful noise. It kept running but it was so loud my Dad came outside bc he heard us coming down the road. It was thumping and whining like a car without transmission fluid.

We took in up to the Ford Dealership and they kept it for about 4 days and when we picked it up they told my Dad they had to replace the WHOLE rack n pinnon part. My Dad was shocked and asked to see it even though the van was under warranty he wanted to see it. They told my Dad that there was a valve or something in that part that needed to be replaced and they could not do it with out replacing the WHOLE thing.

It started making the noise again last week so about 8 weeks after the first repair. Since I am at home I called the Service Department of the Ford Dealer I bought it from and took it right in. He was nice and took the ride with me to hear the noise. He told me I needed to leave the van. This was about 1:00 pm Monday. They called me about 5:00 pm Monday and told me they had arranged for a rental car.

I called them today to see the status and actually drove over there and they told me they are once again replacing the whole rack n pinnon system. Now they can not tell me why it failed again after 8 weeks.

They are telling me nothing except they are fixing it!

I have done some research under NC law and know it needs to be 4 times before the van is considered a lemon. I have filed a report with the NC Motor Vehicles etc. I called Ford and spoke with a guy who could careless and told me Ford would continue to try and fix it and then it could go to arbitration.

I don't even want a new van. I actually like my van but from my calls to other Ford Dealers and mechanics and family this rack n pinnon going out like this again signals red flags. The valves are not getting washed out and metal is getting int the system and such.

Help me, the Ford Dealer is suppose to call and says the van will be ready today. If I go and drive off how will I know my steering won't fail us again and hurt my young boys.

I can not find any information on people having this type of problem so someone help me.

Thanks!
Tiff

Gamecockinnc

Just a quick update the Ford Mechanic working on the van just called and said he has fixed the problem. He said he is hearing a "rubber" noise and wants to keep the van to go over it more then have me pick it up in the morning. I told him ok but the last time when I picked it up it sounded fine for a few weeks so I doubted it would "act up" in the 10 minute ride. I also asked him if the first Ford Dealer put a new or rebuilt pinnon part in it and he said it was rebuilt which is common with Ford but he did not say what he put in it this time. He also said he fixed a "leak" and the first mechanic 8 weeks ago just noted in the Ford computer system problem running............

sahib

You said your Dad wanted to see the original defective rack and pinion. Did they show it to him or not? Sounded like they didn't. If not, they probably did some in house repair on the old one and called it good. That would explain why it is once again acting up. Insist on seeing the replaced one this time and get them to give you some explanations as to why it malfunctioned. Yours and your family's safety is at stake here. Don't know what to tell you if they tell you to bug off. Guess I'd try to get through to someone more caring at FoMoCo. Good luck.

P/S I don't know how warranties work for these new vehicles (I haven't bought new since 1968) but would think they should be replacing defective parts with new not used or rebuilt.

Gamecockinnc

Yes they did show him the part (rack) they took out. Of course I did not know to ask if the one they put in was new or a "rebuild". The Ford Dealer in SC showed my Dad the part they had replaced which was the whole rack n pinnon system and told him that there was a problem with a valve inside the rack n pinnon system. My Dad asked why did they not just change the valve and the guy told him bc you can not get to it you have to replace the whole part.

Now 8 weeks later same van is making the same noise and I take it in to the Ford Dealer here in NC I purchased the van from. He tells me the rack n pinnon is leaking but not enough I should have noticed or to cause a problem. I tell him that is a very good answer since:

1. It is making the same noise and we are unable to turn like the first time so leaking a little or a lot I knew it was bad again.

So the Dealer still has it and I am suppose to get it at 8:00 am tomorrow morning. I am not happy. I have not gotten a straight answer from anyone.

Has anyone else had these problems with their 2002 Windstars?

irish30

Ford is replacing rack and pinnions (steering racks) on all types of vehicles. Mustangs, explorers, windstars. You can insist that a motorcraft brand new part be installed but they may not do it. These brand new parts are more expensive and under warranty Ford doesn't want to put out more than they feel they need too. The bean counters help keep Fords warranty costs low. One choice you do have is to drive the van and maybe not be able to steer for an instant and drive into something. Then call a lawyer and tell them the circumstances. You can also send a nice descriptive letter to your local news paper or T.V. station about what has been going on with the repeat repairs. The same letter you send to them is the same letter you send to Ford letting them know you have taken some actions to warn people about the dangers of Ford replacement parts. This should open an eye or two. If you make a fuss they will tend to help more. It's not right that you need take actions like this, but to them this repair is a daily occurance.

Gamecockinnc

Update:

Thanks for the answers some of you have taken the time to post. For any new readers I have a 2002 Windstar SEL with 29,000 miles on it and it is 20 months old.

The rack n pinnon system went out on me while visiting family in another state in March and was replaced and went out again (leaking valves both times is what they call it) and another new one was put in yesterday.

I went and picked my van up today and did the test drive and of course it was fine because it has to be running for awhile to cause problems and usually have some time between problems.

I waited until I was done and then I got paperwork this time with all of the details. I then went to the new sales area where I purchased the car almost 2 years ago and asked for the sales manager. Long story short I asked to speak with him in private and told him the situation and he acted very understanding. They were so concerned (lol) they wanted to keep the van longer and then give me a 2004 Freestar to drive which is just like my Windstar but a few changes. I took it and then while moving my car seats to the new van they introduced me to the owner......strange.

Off I went and then they called me later with outrageous figures to trade in for the new one. Right now I have 0 % financing and am 20 months into it so I have made a good chunk in principal down. I said no. I was naive and honestly thought they were trying and they did admit that 3 rack n pinnons systems was not common or acceptable.

I just said no and I was coming to get my van. I then have to leave and go get my oldest son from Kindergarten so I take the Freestar and it almost breaks down. The Dealer called me back on my cell phone bc they knew I was upset and I could not even talk to them. When I had the traction control on the brake lights, ABS lights came on and the transmission went crazy and I could go about 20 mph with a awful noise and had to pump the brakes. When I turned the traction control off the van shut down and I could go 10 mph almost with almost no brakes. I was hysterical, I had had it.

The brake light, ABS light, check traction control message and everything was going off and the brakes were failing and the van was making a awful loud noise.

Somehow I got my son from school got in that dang Freestar drove to the dealer pulled up next to my 2002 Windstar SEL. I started taking the car seats out of the new loaner and putting in mine and the dealers were just watching me like "oh man she has lost it". I did not yell I just did a mans worse nightmare I cried. I was so mad I just kept crying. All of a sudden the Owner of the Ford Dealership walked up and seemed concerned and I told him I was too upset to talk to him. I had been thru 3 rack n pinnons on a Windstar SEL with less than 29,000 in 20 months. I was upset, the new improved Freestar just broke down on me and I had it with Ford and with them. He seemed like he was going to cry. He said he would call Ford and notify them and I said I already had started a "record" and that I also filed a vehicle complaint with the AG of NC and he was trying to rip me off when he sold me a brand new lemon and no one would own the problem.

I am not able to just give up 20 months of over $500 a month payments at 0% to go upside down on a new 2004 Freestar that just broke down so it may have kinks too.............turns out they called me back awhile ago and now are almost able to break even with me on my trade but are playing the retail to retail (MSRP) and such. I would still be upside down $2450 and then start another 60 to 72 months of payments at 0% or 2.92% but lose out on the 20 months of payments that knocked down the principal.

Ford has also offered to give me a "free" 5 year 100K warranty.

I think I should take the free warranty instead of going upside down but then having the whole rack n pinnon replaced 2 times in 8 weeks scares me for the safety of my family.

I also just received the recall notice for the 2002 Windstar SEL that the captains chairs and 3rd row did not meet requirements etc.

I am scared my steering will go out again but then do not know if I should take the chance of the newest repair and free warranty or just trade in for peace of mind and safety but then what was the deal with the brand new Freestar they gave me that went bonkers.

Also the Dealer called and told me they took the Freestar they gave me for a ride and it was in repair now and it was the second one they had that had traction issues..................

Thanks for letting me vent. I had to stop crying.

Skip202003

how do you remove a steering rack on a 1999 Windstar?

2tru

In reply to Gamecockinnc: This is just my opinion, but I think, if I were in your shoes, and if I understand the terms they quoted you, I would take the Freestar, if it were brand new, off the showroom floor, and demand a full warranty be included (at no additional charge, of course). I understand that you would be paying for another 72 months. However, since the vehicle you are currently in is not worth the ink on the title, you will probably not have much of a vehicle once it is paid off, and you will need to buy another one anyway. This way you are actually getting a lot more for "trade in" than you would normally. As I said, just my opinion...