Recall complete- New problems reported?!

I got the call from the dealership today that my van was ready to pick up but it won't pass inspection for there is a misfire engine code now and they want to fix it. They put the axle brace kit on in the first week of March and then failed the front sub frame. They also want me to turn in the rental car tomorrow. I have read that this is common for the vehicles have basically sat for months on end (three months now). This time has had very cold snowy conditions to temps in the nineties with high humidity. I know for a fact (complete recent tuneup) that the van had NO engine codes related to misfires prior to being let sit for months with 3/4 tank of gas that contains 10% ethanol. I also am sure that there is a really good chance that I will have brake issues for the same reason (months of sitting). Has anyone had to fight with the dealers over these issues? I hate to take the rental back if my van is not fit to drive.

YES...Just got my van back after sitting for 3 months in Michigan weather. The brakes are surging, it feels like a warped rotor, and it runs like $hit. We are using that last tank of gas now, and plan to fill with premium and some sea foam. We had the front and rear done as both failed like yours. I would not turn in the rental and speak with the service manager about your situation. I dont mind getting loud to further my case with them. Just my 2 cents.

I spent a half hour on the phone with the service dept. and basically they are saying the rough running situation has nothing to do with the recall work and Ford won't cover any tank draining, etc..... I will get the tank drained tomorrow and put all new gas in it with some more treatment. I put two bottles of ethanol treatment in it when stored and one more during the three months that it was at the dealership. I guess Ford is also not being cooperative with the dealership for the service manager said he has had this exact same conversation with about 80 people so far. I have to say that I can't blame the dealership as much as Ford. Luckily I have lifetime brakes at Cole Muffler so if I have a brake issue I will take it into them and hopefully it will be covered by them. I am worried that driving the van with it coughing and sputtering will make matters worse, so like I said I will be getting the tank drained right after I pick it up.

I ran the tank of gas with all the additives out and put in fresh premium and still ran like crap. Went to another dealer (Chevy) and they diagnosed the coil pack as being bad. They also mentioned moisture in a connector related to this. The van runs great now and when I was under the van to replace the fuel filter the week before I looked over the brackets and I must say I am impressed with the size and strength of the bracket fix. They really did put a lot of steel in place. I was under the impression they were just putting some small brackets on the ends, but they put some really tough brackets on.

when I was under the van to replace the fuel filter the week before I looked over the brackets and I must say I am impressed with the size and strength of the bracket fix. They really did put a lot of steel in place. I was under the impression they were just putting some small brackets on the ends, but they put some really tough brackets on.

any photos to share?

It is VERY good to know that you have the issue solved.
Thanks for posting the outcome.

I ran the tank of gas with all the additives out and put in fresh premium and still ran like crap. Went to another dealer (Chevy) and they diagnosed the coil pack as being bad. They also mentioned moisture in a connector related to this. The van runs great now and when I was under the van to replace the fuel filter the week before I looked over the brackets and I must say I am impressed with the size and strength of the bracket fix. They really did put a lot of steel in place. I was under the impression they were just putting some small brackets on the ends, but they put some really tough brackets on.

The steel brackets on my van are hitting the muffler pipe when the vehicle runs over a big bump. I had to get my muffler fixed 2 times in last 3 months. My exhaust system is only 6 months old front to back.

The strong big clamps are another POOR design from FORD, without thinking of the muffler lines.

I just looked at the rear axle fix on my '00 Windstar, just to verify, and took this picture:

http://good-times.webshots.com/photo/2800515210056340866TCczOc

There's a semi-circular cutout on the reinforcement bracket, to avoid hitting the exhaust. Mine has had no problems hitting.

Do you have an OEM exhaust on your van? Is there some reason the exhaust pipe isn't lining up with the cutout in the bracket?

I just looked at the rear axle fix on my '00 Windstar, just to verify, and took this picture:

http://good-times.webshots.com/photo/2800515210056340866TCczOc

There's a semi-circular cutout on the reinforcement bracket, to avoid hitting the exhaust. Mine has had no problems hitting.

Do you have an OEM exhaust on your van? Is there some reason the exhaust pipe isn't lining up with the cutout in the bracket?

First time I thought the same as it alligns perfectly fine. However after the second break, I saw the dent on the side of the pipe. I have now moved the exhaust higher up by rewelding the hanger bar.
Yes ....my new exhaust line is non OEM.