Rear Axle Crack

Guys,

I have a crack in my rear axle where the ac drips on the axle. Garage said it wil fail inspection if not replaced. Anyone weld theirs ? Did it pass then? Did it hold up ? I'm going to take it somewhere else if it will pass.

Thanks,

AJ

Your dealership should have information on the RECALL from FORD about the rusting rear axle.
As a RECALL (vs a TSB), it would be repaired for FREE.
This is on 1999 through 2003 Windstar.
This recall is just now coming out (I read a notice that was issued by FORD just this weekend to the media).

A link to a thread about this
http://www.automotiveforums.com/vbulletin/showthread.php?t=1038765

Wiswind,

Thanks ... do you have a link or know which publication you saw this. Checked Google and didn't find anything about RECALL?

AvalonJohn

Well I am glad they are doing something about this. All this is just coming to light with my 2002 with only 66k miles on it. While looking into abs sensor issues I saw a crack in the rear axle. Crimeny I thought a new axle! So I came on here and did some research along with Google and found out I am not the only one with a cracked rear axle. Well here I was thinking well I will take it over to my buddy's who is a welder and have him weld on some plates. Doing the prep work for him so all it would take is minimal time for him, I noticed a second crack as I was crawling under there. Using my scale I scraped a little bit of the corrosion off and poke a little and low and behold it started to cave in. Super yikes right?

I notify buddy about it and we both came to the conclusion that welding will not solve the problem as the arc welder will more than likely just blow through the whole material.

Keep up the good work all, I stop in now and again when I am having issues with my van.

Taking the van to the dealer on Monday and am going to hold them to task on it. Will let you all know how it works out, and I will be bringing up the front end corrosion with them as well.

Here's the links to the NHTSA reports.
http://www-odi.nhtsa.dot.gov/cars/problems/defect/defectsummary.cfm?inv_id=19565&type=VEHICLE&typenum=1&cmpt_id=22&prod_id=215156&make=FORD&model=WINDSTAR&model_yr=2002

http://www-odi.nhtsa.dot.gov/cars/problems/defect/defectsummary.cfm?inv_id=19606&type=VEHICLE&typenum=1&cmpt_id=22&prod_id=215155&make=FORD&model=WINDSTAR&model_yr=2001

Seizer,

You should report this (if you already haven't) to the NHTSA, otherwise Ford will continue to get away with this crap. More reports more likely a recall for the axle. Go to the site, takes 5-10 mins to register the complaint. You car has low miles too. Fords been saying that all the vans that are reporting the problem have at least 100K plus on them. Reporting to NHTSA with 66K will help a recall.

AvalonJohn

To all Windstar owners, www.mycarstats.com (http://www.mycarstats.com) has a long list of complaints regarding broken rear axles.(and transmisson failures) Register with my car stats and you'll be in for some surprising, interesting, and annoying reading. NHTSA and Ford have known about this situation.
I inspect my rear axle at every tire rotation.

I'd get rid of the van, but like others here, I can't afford another vehicle.

I was at the dealer today on the brake switch recall and they knoew nothing about an axel recall at this time.

You should report this (if you already haven't) to the NHTSA, otherwise Ford will continue to get away with this crap.
AvalonJohn

Done its been reported. Took the vehicle today to the dealership and told them to take care of it. They gave me the run around and said they wouldn't fix it. Their lame attempt to inspect the axle so that I had ammo for Ford was pathetic. The service manager barely crawled under there and didn't even note the two nice cracks I have in it. I've been emailing Ford and so far the representative I am dealing with seems to be helpful. Will keep you all informed.

can someone give me more detail as to where the cracks are occuring? both on the rear axle and front subframe? is it seen from the top, bottom, sides?

someone mentioned the rear a/c dripping onto the axle but that looks like it's 8" behind the axle? it's not directly underneath.

tia,
parker

I was at the dealer today on the brake switch recall and they knoew nothing about an axel recall at this time.

Funny that the dealers know nothing about the rear axle problems but that thats what they look for to fail the car during inspection - only thing my car failed for. Longer Ford can hold everyone off the more they save. No wonder everyone is buying japanesse cars. They stand by thier mistakes. They bitch, but they take care of them too.

AJ

Rear Axle is on the drivers side about 1/4 of the way in from axle. Many failers are in the exact same spot. i.e. that's a defect !!!

John

Rear Axle is on the drivers side about 1/4 of the way in from axle. Many failers are in the exact same spot. i.e. that's a defect !!!

John

so it's the trailing arm, not the axle?

No it's on the rear axle about 1/4 in on the axle - drivers side.