Rear axle beam possible recall 1999 to 2003

It seem that an investigation is presently done by the National Highway Traffic Safety Administration for the rear axle failure on the Windstar year model 1999 to 2003. We just hope that this investigation will be followed by an official recall. A few crashes has been report following rear axle "snapped in half" The following can be seen on the NHTSA web site.
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NHTSA Action Number : PE10016 N/A NHTSA Recall Campaign Number : N/A
Make / Models : Model/Build Years:

FORD / WINDSTAR 1999-2003

Manufacturer : FORD MOTOR COMPANY
Component :
SUSPENSION

Date Investigation Opened : May 13, 2010
Date Investigation Closed : Open
Summary:
The Office of Defects Investigation has received 234 complaints alleging rear axle failure in Model Year 1999 through 2003 Ford Windstar minivans, including two alleging that the failures resulted in minor crashes. Over half of the complaints (128) allege a complete fracture of the axle beam. 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 pot hole. The driver indicated that both rear tires "blew" (note that axle fracture often causes the tires to achieve a severe negative camber - with the top of the tire tilted inward - resulting in contact with the fender well). The vehicle then struck a guard rail because of difficulty controlling the vehicle while braking to a stop. The second crash was also alleged to have involved a complete axle fracture, in this case resulting in a low-speed curb impact. 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. Approximately 96 percent of the complaints (225), 94 percent of the complete fractures (121), 96 percent of the high-speed incidents (54) and both alleged crashes are from "Salt-Belt" states. In addition to the two alleged crashes, 14 additional complaints alleged vehicle control concerns associated with the rear axle failure incident. A Preliminary Evaluation has been opened to assess the scope, frequency and safety consequences of the alleged defect in the subject vehicles.

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The rear axle beam on mine broke while my son was driving it. Luckily, he was in a park and going slow. I guess I owe him an apology! Luckily, it was a fairly easy (albeit expensive) fix.

In my home town, the garage that does all the collision work and also alignments always checks that rear axle beam for cracks. If found, he welds them up. I have another friend who has a taxi business and runs Windstars and has had a number of them welded.

So the problem is widespread.

Also, remember to replace bad hub bearings IMMEDIATELY because the stub shaft will BREAK OFF before you expect it. A friend's son, who is a Mercedes mechanic, had that HAPPEN TO HIM!!!!! His dad got to him while he was still strapped in the van upside down and as white as a ghost(!)

The rear axle on my 2002 was also cracked and caused a loud popping noise while turning right up a driveway. The brake light would also come on after the popping noise. An independent garage found it.

No thanks to my local Ford dealer in La Crosse, WI that acted like they never heard of it and never let me know it was cracked during a recent oil change. They said it would be $1,000 to fix.

Also no thanks to Ford customer service who also acted like they never heard of it even though the NTHSA investigation was already announced. They said a repair would be my responsibility.

I will never go back to that Ford dealer and never buy another Ford.

Another independent garage welded it for me for $88.00 today. The popping noise is now gone and the brake light does not come on.

So to protect yourself and your family, please check your van inside the U of the rear axle about 12-18 inched from the driver side. It cracks directly under where the rear air condensation drips on the axle.

.............. It cracks directly under where the rear air condensation drips on the axle.............

I agree with this conjecture. I think a full "fix" would include added foam insulation to the ac lines to prevent condensation.

Does that mean only rear air condensation drip "breaks" the rear axle beams?

It's a combination of things, ... but the condensation drip is very important, I believe.

Observations and theory:
1. All axles seem to break in the same location ... where the condensation drip occurs. My 99's rear axle is nowhere close to failing, but I can see where the early drip-errosion has begun. Thus far, the errosion on my axle has not gone thru the paint... but it is precisely where all axles seem to break into.
2. All Windstars with rear ac have a flood of condenstion dripping from the rear unit ... some comes from the cooling coil and is "expected" ... some drips down from exposed refrigerant tubing. Condensation is very pure water ... a very good solvent, especially for salt ... the water and salt would be a powerful rust engine.
3. The problem could have been prevented by better corrosion protection on the axle ... better condensation control ... or a combination of both.

... all my unproven theory.

Mine broke about a foot from the passenger side, and I don't have a rear AC unit. $1000 seems pretty steep, although maybe not, seeing as the axle cost $200 at the junkyard. But it was fairly easy to replace.

Just got back from Ford dealership. Have a small hole in the rear axle assembly and it's cracked. $ 700 to fix .......... sounds all too farmilar. Hoping for a recall. Maybe I'll look for the part somewhere else and have them install.

AvalonJohn

Just got back from Ford dealership. Have a small hole in the rear axle assembly and it's cracked. $ 700 to fix .......... sounds all too farmilar. Hoping for a recall. Maybe I'll look for the part somewhere else and have them install.

AvalonJohn

You might want to try doing it yourself. It's not that hard of a job, especially if the axle hasn't broken. I paid $200 for a used axle at a junkyard, and it took a couple hours, and mine had broken. We'd be happy to help you through it, too. :)