Recall

Just heard on the news that our Windstars are up for a recall for the cruise control. Without getting too much info from the news, do you think it is for the brake pressure switch that most of us had to replace already? If we have already replaced the part, do you think they will refund the money we spent on the part?

I just read that the Windstar has been added to the recall list.....1995-2003 Windstar.
Those of us who have already replaced the switch should check to make sure that it is the improved one.....or harness.
They used the "faulty" Texas Instruments switch up into 2003.
The "fix" is...as stated on Yahoo Finance " To repair the problem, dealers will install a harness to help prevent the fluid from flowing anywhere it could be ignited."

We should all be getting a letter from FORD that explains what to do.
Hopefully they will have the part(s) in stock to cover all the vehicles covered.....as it includes a LOT of different vehicles.
This time, they are including ALL the vehicles that use this same switch.

Simply unplugging the switch may not solve the issue for a leaking switch.....as one needs to be concerned about any electrical items that the leaking brake fluid may drip on.
The Yahoo Finance article mentions antilock brakes (the article covers other FORD vehicles in addition to the Windstar), however....several folks have mentioned the cruise control servo unit as being burned out by brake fluid.
Also, the Transmission Range Sensor (TRS), aka Neutral Safety Switch has been mentioned as a possible issue for dripping brake fluid from the switch.

I would not expect to be refunded for switches that have already been replaced.....but, as I recall.....it was a pretty cheap part (Less than $20) including the harness and a bottle of brake fluid......but if they do....they should mention it in the letter.

One data point: I replaced the switch in my 2000 Windstar in June 2007, using a kit I purchased from the dealer (Ford part number XW7Z-9F924-BA). This included a new switch and the small jumper harness. Total cost then was $26.72. Yeah, it'd be nice if the recall covered the cost of switches already replaced. I've got to believe that virtually all of them older than my '00 have already failed.

I think we can all thank Scott's excellent website below for keeping this issue forefront with the NHTSA. Those not familiar with the link should review the info there as it is being updated to keep up with the new recall.

I also bought this switch kit from Ford last year and saved the receipt. I plan on getting my ~$25.00 back from the service department... I saved them the labor, they can pay me for the parts...

Now if only they would recall the ABS module, I have the C1185 relay code error when ambient air temp is above 50 degree's F. At least the ABS works in the winter...

http://www.fordwindstarrecall.info/

bdahl385 -

Thanks for the link! I hadn't seen that site. Yes, it'd be nice if they came through on the ABS module, too (I replace mine with a new Ford unit, and all has been well - but I don't want to see that problem return).

Question: As noted above, I replaced the master cylinder cruise control switch on my 2000 Windstar with a new Ford dealer-purchased part in June 2007. Is that switch likely the most current design version, or does this recall specify yet another design?

Let it never be said that my procrastination didn't yield positive results. :biggrin:

The switch in 2007 "should" be the most recent.
However, you will likely still get a letter....and they should look at it for free to verify that it is up to date.

Maaannnnn...... I have a Windstar that fits that year but it's a base model, meaning NO cruise control. Meh, I have enough problems with it w/out worrying about yet another recall.

I work at a dealership as a tech, and yes there are instructions for refunds, as I just fix them, you'd need to call and talk to a service writer for specifics on what to do. With the switches, more of the windstars melt and get heat damaged from leaking than any of the others I see. If a switch is found to be leaking, it gets replaced, the cruise servo gets inspected, as well as the abs module. The damage to the wiring gets repaired, should be free, if your dealer calls ford to get it approved as related damages.
TO TELL IF YOU HAVE A NEW STYLE SWITCH is easy, the new style switches have a more round looking conector, the old ones are rectangular.
If a switch is not leaking, a fused harness is installed inbetween your car's harness and the switch. The fuses will blow before any damage occours to the vehicle, or fire for that matter. The harness takes about 5 min to install, and after the harness is in place, it is no longer ford's problem if the swith leaks because it won't cause fire (the original reason for the recall).

Hope that sheds some more light on what really goes on/supposed to go on.

Maaannnnn...... I have a Windstar that fits that year but it's a base model, meaning NO cruise control. Meh, I have enough problems with it w/out worrying about yet another recall.

Don't worry about that, the Windstar have hundreds of recalls (without being sarcastic). This one is the only one serurity recall. Unless you see brake fluid leaking, do nothing.

The see it leak theory is good, but most only seep, which you won't see, there is a difference between leak and seep, the fluid works its way on the inside of your tape covered harness to other higher amperage parts, then lights up. I see these at work, and as much as I don't want to see another one of these for the recall because I've done so many, it really should be checked at your soonest chance. If nothing else, you won't get anymore letters.

Oh, and no cruise control means no switch. and ford only recalls X number at a time, so your recall might not come up until you get your letter even if you have a van that qualifies.

Make: FORD Model: WINDSTAR
Model Year: 2001
Manufacturer: FORD MOTOR COMPANY Mfr's Report Date: OCT 09, 2009
NHTSA CAMPAIGN ID Number: 09V399000
EA08021
NHTSA Action Number: EA08021
Component: VEHICLE SPEED CONTROL
Potential Number of Units Affected: 4500000
Summary:
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence:
A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy:
FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR ABOUT OCTOBER 26, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
Notes:
FORD'S RECALL CAMPAIGN NUMBER IS 09S09. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .
Check to Request Research. Submit below.

I can see some fluid under the brake switch of my 2000 van. Will a ford dealer do the repair even if I am not contacted by Ford on this recall yet ?

They will not contact you. You should contact them. Check in this Website if your serial number is listed: http://redirectingat.com/?id=252X400&url=http%3A%2F%2Fwww.fordwindstarrecall.info%2F (http://redirectingat.com/?id=252X400&url=http%3A%2F%2Fwww.fordwindstarrecall.info%2F).

They will not repair all the vehicles at one time. You may be listed later.

I checked the web site. Could not see where I could check the serial number. I must be miss reading (not reading) a line some where. I have an appointment with a Ford dealer for Wed. He was aware of the recall. I am sure he is going to check before doing repairs...........Thanks for your info.

Took the 2000 van to a Ford dealer. They replaced the switch. No questions asked.

Took the 2000 van to a Ford dealer. They replaced the switch. No questions asked.

Which questions can they ask anyway? "Do you have the bill of the car?" :lol:

Which questions can they ask anyway? "Do you have the bill of the car?" :lol:

I thought the dealer would inspect the switch and replace it ONLY if it was leaking. The questions they could have asked:
-Have you received a recall notice from Ford ? if `no' you have to wait.
-it's not leaking why do you want to have it replaced ?

see, there are two. I am sure they could have asked others.

Please NOTE, this recall applies for vehicles with or WITHOUT cruise control.
This is stated in the recall notice that I got from FORD today.

I just receive a letter from Ford for the recall safety.
What's cool is that I didn't had to anything, they send me the letter for that.

Recalls can be refunded. You go to service dept. Show them your bill from when the part was replaced, the Bill has to have date, mileage, vin # on bill or ford will not refund the money to you, And lastly it has to be within Mileage limits for that particular recall.

To the ford tech that commented here on the recall. If they install a harness and the fuse blows later on what happens to the vehicle? does it shut off or can you still drive with the fuses blown? If it shuts off then i would be better off just buying a new switch. I had the harness installed yesterday. It took the tech less than 5 minutes to do the harness. By the time i was signing the paperwork he had already finished. My concern now is what happens if the fuse blows.

While I'm not a Ford Tech, I've spent some time on this issue:

If the fuse blows, your van will still be drivable. The only symptom you'll likely notice: The speed control system won't work if the fuse blows (or the switch fails).

Yes, and also the brake lamps. And the ABS.

Yes, and also the brake lamps. And the ABS.

No.

At least not on my '00 Windstar LX.

Brake lamps are handled by the switch attached to the brake pedal, inside the cabin. ABS is also handled separately.

Why do I know? My '00 went around with this switch disconnected for some time, while I was researching this problem. ABS and brake lamps worked without problem.

No.

At least not on my '00 Windstar LX.

Brake lamps are handled by the switch attached to the brake pedal, inside the cabin. ABS is also handled separately.

Why do I know? My '00 went around with this switch disconnected for some time, while I was researching this problem. ABS and brake lamps worked without problem.

I know. I talked about blown brake switch's fuse.

The Brake On Off (BOO) switch....in the passenger compartment.....up under the dashboard....connected to the brake pedal shaft.......is in a different circuit.
What happened with mine is that one of the wires broke off of it.
When this happens (open circuit), you cannot shift out of PARK with the motor running.
You have to shift into Neutral, start the vehicle......and then shift into drive.
HOWEVER, you will have no brake lights on the back of the vehicle....which is very dangerous.
From what I have read......this same switch will disengage the Cruise control as well......in addition to the brake pressure switch on the bottom of the master cylinder.

So....in short....If the fuse on the brake pressure switch goes open (blown), you will have no cruise control......but no other problem.

Thanks to everyone for the replies. At least now i know i can still drive the van. I don't use the cruise often so it won't be a problem. Once again thank you.

I just check in my schematic, if the fuse on the brake pressure switch blows, you'll get no cruise control and no ABS. But no other problems.

That the ABS Control Module damage is covered under this recall. Husband and I just took my van in today because I'd been having ABS issues (when car starts, ABS are engaged for several minutes before they turn off and ABS light appears) and had been randomly noticing a burning smell.

Got a call back from the service dept saying we needed to have our ABS control module replaced. They didn't mention this recall at all, I just happened to stumble across it while researching.

Husband plans on mentioning this to the service dept tomorrow, but I was just curious whether this issue can cause the ABS module to fail?

No, the brake pressure switch recall cannot cause the ABS module to fail, but it can make it stop working.

But only if BOTH your cruise control AND ABS stop working at same time, it's related to this recall.

Otherwise, it's no related issue.

Here is a link that I found very helpful in regards to this matter:
http://www.fordwindstarrecall.info/#Problem1

I have a 2002 Windstar that had the harness recall performed, yet now I am still getting the ABS/Brake lights on most of the time. The problem appears to the the ECU with a $852.00 estimated cost. There is a link to report this issue/defect to the proper authorities.

Here is the link to report the problem: NHTSA.GOV. (National Highway Transportation Safety Administration) (http://www-odi.nhtsa.dot.gov/ivoq/). Use this link (http://www-odi.nhtsa.dot.gov/ivoq/). or call 1-800-327-4326.

Hope this helps. I just reported the issue this morning.

I had the #10 fuse blow and had the harness/switch replaced in my 2001. After 3 fuses blowing I disconnected the switch, the fuse now doesn't blow, I now have gauges and AC in th 100 degree weather.

There will be another recall for Windstar 1998-2003 models for rear axle break issue.
http://www.thecarconnection.com/marty-blog/1048757_1998-2003-ford-windstar-minivans-recalled-for-rust-issue

1. NHTSA Campaign ID Number: 11V030000
Recall Date:
2011-01-26

Summary:
FORD IS RECALLING CERTAIN MODEL YEAR 1999-2003 WINDSTAR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, UTAH, VERMONT, WEST VIRGINIA, AND WISCONSIN. A SEPARATION OF A FRONT LOWER CONTROL ARM REAR ATTACHING BRACKET MAY RESULT IN A LOWER CONTROL ARM SEPARATION. A SEPARATION OF BOTH FRONT SUBFRAME REAR BODY MOUNTS MAY RESULT IN SEPARATION OF THE STEERING INTERMEDIATE SHAFT.

Consequences:
THIS COULD RESULT IN REDUCED STEERING CONTROL INCREASING THE RISK OF A CRASH.

Remedy:
DEALERS WILL INSPECT BOTH FRONT LOWER CONTROL ARM REAR ATTACHING BRACKETS, AND BOTH BODY MOUNT ATTACHMENTS AT THE REAR OF THE FRONT SUBFRAME, AND MAKE THE NECESSARY REPAIRS FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 14, 2011. OWNERS MAY CONTACT FORD AT 1-866-436-7332.

Component Affected:
STRUCTURE: FRAME AND MEMBERS:UNDERBODY SHIELDS

Potential Cars Affected:
425,288

Notes:
FORD MOTOR COMPANY

I can honestly say that Ford's handling of this recall has been absolutely dismal... and if I am a shareholder, I would be out for blood.

We turned in our Windstar around Halloween... and just received it back this week..

Meanwhile they paid $4600 to Enterprise for our rental... then I am guesstimating 1800 for the axle repair... and then they had to fix all the pieces parts from sitting for so long...

Why not just make everyone a flat offer and save yourself the headaches Ford?

I can honestly say that Ford's handling of this recall has been absolutely dismal... and if I am a shareholder, I would be out for blood.

We turned in our Windstar around Halloween... and just received it back this week..

Meanwhile they paid $4600 to Enterprise for our rental... then I am guesstimating 1800 for the axle repair... and then they had to fix all the pieces parts from sitting for so long...

Why not just make everyone a flat offer and save yourself the headaches Ford?

They made us a buy out offer that is 150% of book...which is nice and will be put toward another vehicle, but they are only giving $300 for a rental! We are figuring 4-6 weeks for the settlement to arrive. So what do we do for a month and a half Ford?

Let it never be said that my procrastination didn't yield positive results. :biggrin:

Well said - and I echo his chorus!

I need to get this done soon now I guess.:biggrin:

A Windstar without the check engine light is not a real Windstar.

LMAO!!:lol2::lol: I just cleared my Check engine light again... My Cousin drives ford too and he said that on a ford the engine light means that you have an engine - it's supposed to be on!!
LOL!!

My 2000 was recalled for Rear Axle and Front Cross Member and I nearly rolled it because they did not tighten the main suspension bolt on the RHS lower trailing arm on the rear axle.

The bolt fell out making the RHS of the rear axle UNCONNECTED TO THE FRAME!

It was very interesting going over dips and applying any brakes on LH turns was a pure adrenaline rush.

I called the Ford service department and they said "bring it in an we'll take a look at it." I asked for a manager and clearly told him the RHS of the rear axle was "flapping in the breeze" and wouldn't it be safer to send a mechanic with a bolt and a floor jack to install it where the van sat? There could not have cared less - it was like I was complaining because someone left a smudge on the door after a service call.

What complete IDIOTS.

And I don't even want to get into the butcher job the front crossmember was. First the engineering design is something you would expect from a department run by Dr. Seuss. Now the van tracks to the right and there are big nasty banging noises like something is loose in the front suspension.

Maybe its ready to fall out.

Oh, I was able to drive it to Ford since I am used to doing stuff like that. They fixed it and never wrote any paperwork on it. Again, they were almost uninterested when I showed up.

Maybe they are instructed by their Legal Department to act all mellow when they screw up and expose themselves to a potential lawsuit.

Anyhow, that's my story(!)

Regards,
Tom

What complete IDIOTS.

And I don't even want to get into the butcher job the front crossmember was. First the engineering design is something you would expect from a department run by Dr. Seuss. Now the van tracks to the right and there are big nasty banging noises like something is loose in the front suspension.

Maybe its ready to fall out.

Oh, I was able to drive it to Ford since I am used to doing stuff like that. They fixed it and never wrote any paperwork on it. Again, they were almost uninterested when I showed up.

Maybe they are instructed by their Legal Department to act all mellow when they screw up and expose themselves to a potential lawsuit.

Anyhow, that's my story(!)

From what I heard this varies widely from one dealership to the next. After I had the rear axle done (sort of, since there was nothing wrong with it) Ford kept sending me letters about the front subframe recall but my subframe looked fine so I ignored them, but after two years and 8 letters or so I gave in and brought it in last Fall. They did not have required parts in stock so they kept the van for 13 days instead of overnight as expected but no biggie, in the meantime I was driving an Explorer from Enterprise, courtesy of Ford. I had asked for a vehicle with same cargo capacity and on that particular day Enterprise was out of Caravans so they said the alternative was "standard SUV", fine with me. BTW the Explorer does not have the same cargo capacity as the Windstar, it's big outside but cramped inside. It has very obtrusive wheel wells and cabin height from floor to ceiling is less than the Windstar, and the interior cab length is also quite shorter. Only a full-size SUV would approach the cargo space of a stretched minivan like the Windstar but there's no cost efficiency there. I was impressed with the Explorer's extra-smooth transmission and the impressive amount of power it extracts from the 3.5 engine however, all the while getting better mileage. But on the other hand the ride is a little 'dry' (as in truck-like hard and firm) and it's an expensive vehicle. But I digress.

Anyway after I picked up the van it handled a lot worse than before and shortly after both ball joints were shot although I had installed new Mevotech control arms a few months prior. I brought it back without warning and politely explained the situation. A senior tech drove it for a few miles and told his boss something was definitively not right. To my surprise they put it on a lift immediately and the guy who had driven it briefly examined the main bolts and said the dampers (donuts) were not the right ones, they were for a different model altogether and were both too thick and too soft, which caused the subframe to rock and shift and cause damage to parts attached to it. They offered to replace the whole subframe with a new one and put in new control arms free of charge, but couldn't do it until January.

They also threw in a free alignment but admitted they always do it for that recall anyway. Suits me fine, dealerships have a lower wheel alignment failure rate than most shops according to many credible investigation reports from consumer associations. Since I don't use the van in winter I said okay but let's do the recall in May or June and, jokingly I added "and use the dampers from the box this time", which made them laugh. So June it will be. They could not or would not explain why the wrong parts were used but otherwise I received good service, with friendly and respectful attitude towards me. I don't know if it's a factor but this dealership is owned by a woman and is the second-highest rated Ford dealership in Canada for consumer satisfaction. The highest rated is also owned by a woman.

The van is drivable but it's not pleasant, steering is somewhat erratic especially on bumpy springtime roads and the front end rattles a lot at the slightest imperfection and fuel economy has degraded. We'll see to what degree this is due to the botched job.

Sorry to bring a dead topic back to life but it seems that the website posted above is no longer working and well it would have been nice to at least have a look at it. i just bought a 2001 windstar sport and the dreaded abs light comes on and off intermittently and if this was a recall FORD says it wasn't a recall item in canada and that i am left to pay for the repair to the tune of 1500.00 and i figure the van's not worth the cost as i can replace it for that as i currently have 2 and was wondering if the abs modules were interchangeable


fordwindstarrecall.com

The recall has long since expired.

But there are options out there.

If you can remove the electronic portion of the ABS module from the van, there are services out there that can repair the module. Search eBay for "Windstar ABS repair" for examples. They are currently asking upwards of $100 for this service (and some offer it for much less).

Note that you can drive the van without the ABS electronics in place (of course, the ABS won't work). The hydraulic portion is still intact. Separating the electronic portion from the hydraulic portion - without removing the whole unit - will be difficult if there's a lot of corrosion on the underside of the van. The ABS unit is on the bottom of the van, basically below the driver's seat. The electronic portion is attached to the hydraulic portion with 6 steel bolts - that are threaded into the hydraulic unit's aluminum structure. This automatically creates the potential for corrosion that can make the fasteners difficult to remove without destroying them.

I suspect modules may be interchangeable - but don't know about specific model year limitations, etc.

here we go again :runaround:
http://blog.caranddriver.com/ford-recalls-319000-cars-mostly-windstar-minivans-for-rusting-axles/

Wow: Another try at getting it right.

As it turns out, my axle was in pretty good shape when it went in for the first recall. I remember looking at the newly-added brackets and thinking that it looked like a half-baked bandaid approach. I'll be curious to see what they say about my van, now at 185K-ish miles.

Meanwhile, I wish Ford would do something about body rust. In spite of spending most of its life garaged, both rocker panels have rust issues. My doors are still hanging on pretty well: I recognized that was a weak spot early in the van's life - and I snaked a long tube into the bottom of the door to squirt some 80W-90 gear lube in there. The sticky oil seems to have done a good job preventing corrosion. I wish I had found similar access into the rocker panels...

If you can remove the electronic portion of the ABS module from the van, there are services out there that can repair the module. Search eBay for "Windstar ABS repair" for examples. They are currently asking upwards of $100 for this service (and some offer it for much less).

Note that you can drive the van without the ABS electronics in place (of course, the ABS won't work). The hydraulic portion is still intact. Separating the electronic portion from the hydraulic portion - without removing the whole unit - will be difficult if there's a lot of corrosion on the underside of the van. The ABS unit is on the bottom of the van, basically below the driver's seat. The electronic portion is attached to the hydraulic portion with 6 steel bolts - that are threaded into the hydraulic unit's aluminum structure. This automatically creates the potential for corrosion that can make the fasteners difficult to remove without destroying them.



Some of the services send you the new one for a core deposit. I paid a total of $55 after the core refund and was able to do an immediate swap. It's worked great for me. I used a well established business with a storefront, and they offer a lifetime warranty on the repair, too.

Removing the ECU separately while the HCU is still attached is completely impossible if you have rust, and almost completely impossible still, if you don't.

I just got my recall letter (recall notice 15S27) today, 26-OCT-2015.

Interesting: The letter claims "It may be possible that the rear axle reinforcement brackets were improperly installed." No mention of further corrosion after the brackets were installed (which was the reasoning I read about in some of the news articles when this recall was first announced).

The dealer is to inspect the brackets; if they weren't installed correctly, "...your dealer will replace the rear axle free of charge (parts and labor) if necessary."

It also claims "If you wish to have the rear axle replace for any reason...", the dealer will replace it for $300 (until October 31, 2016). I wish they had offered that option the first time around; I think I would have taken them up on it.

My Windstar now has some of the dreaded rocker panel rust; I wonder if they'll say anything about that. Further, I have AirLift 1000 spring airbags on this van, to firm up the rear end when towing a popup camper. If I get the axle replaced, I wonder if they'll complain about them...

Received my letter today....found this on the internet.
http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/UCM487044/RCMN-15V608-4451.pdf

Wonder if the new axles will have a bracket reinforcement?
Where are these "new" axles coming from? just don't trust Ford anymore.

I would suspect the "new" axles will have a more effective anti-corrosion coating.

I have been keeping an eye on my rear axle and the front sub-frame, looking to see if there is any evidence of corrosion. So far, so good. My van gets little salt exposure, so even though the ac unit runs nearly year-round (dripping down condensate at the rear and the front) there is no paint wear-through ... yet. I keep planning to put more insulation on those ac lines in the left-rear wheel well ... but still haven't done it.

I long ago bought a new sub-frame as the original had some pretty severe road-debris impacts. So far, (422k miles) I haven't replaced it. I will paint on extra protection before replacing ... if ever.

Hopefully, new axles will have proper heat treatment - which was the underlying issue in the first place (see page 7 below):

http://www.paed.uscourts.gov/documents/opinions/13d0548p.pdf

I would suspect the "new" axles will have a more effective anti-corrosion coating.


you never know. i read those toyota frames that were replaced had no greater protection on them than the originals.

True, we don't know. I'm hoping...

Hopefully, new axles will have proper heat treatment - which was the underlying issue in the first place (see page 7 below):


Thanks for that link. I have the Benteler axle. (What a name for an axle!) Interesting that heat treatment was noted as the reason for this axle's failure ... and yet it also is of a totally different design. I wonder if the other axles, that did not failed the test, did so because of heat treatment ... or design. ??

Its interesting to me that cracks can form ... and be noticed, BEFORE failure occurs. It would seem to me that if this were a simple beam "in failure mode", total failure would occur as soon as cracks formed .. with no waiting period.

All photos of the failed axles that I have seen, those that have broken in-two ... and those that have just exhibited cracks ... have had those failures near the bearing hub area on the left end of the axle. This under the exposed ac lines in the left rear wheel well. I have noted, on my axle, that there are "stains" in the paint in this area, and exactly in the location of the cracks and the breaks seen in those photos. I have always assumed that ac condensate is a main contributing culprit ... but it may be just a high-volume water drip area. I haven't looked in quite a while .... I think this weekend it needs to be done.

I wasn't aware of the Benteler name.

Hmmm.... This:

http://www.autonews.com/assets/html/11_pace/winners/1999_Benteler_Automotive.html

...implies that Benteler made all of the later "crushed tube" design Windstar axles. Anyone know if this is correct?

Interesting: In retrospect, this quote from the above article:

...unique zone heat-treating process for flat stampings.

foreshadows the problems we're seeing today.

Thanks for the replies.. The 2000 Windstar is my mothers, she's 84 years old and still driving it to church, I thought we had this issue fixed several years ago with the bracket repair. Now here we are again...very disappointed in Ford. I see others are having problems even after the axle repair. https://www.youtube.com/watch?v=VjE3_7uvfzI

Wow, these are some rusty axles that are failing. If my axle was this rusty, I would not drive the vehicle! I wonder how much was saved by not applying hot-dip galvanizing?

Good morning, all. Just completed my axle recall.

I took our 2002 Windstar to the stealership yesterday, by appointment, to get the axle inspected and replaced. Honestly, it wasn't THAT bad, but decided that, given the age, I opted to spring for the $300 anyway since it costs nearly $500 just for the part and this is obviously a once-in-a-lifetime deal for getting this done. I met with the service advisor yesterday who was obviously not as aware of the details of the recall as we all are on the forum but handled the ordeal very professionally, I felt. I left it with him and he said he'd call me with the results of the inspection within half an hour. When he called, he mentioned that all they found was one tiny crack and that he honestly wouldn't recommend replacement since it was in fairly good shape. [Do realize that they do not make money off of warranty and recall work, contrary to what people think. The labor rate is only a fraction of what it is for a cash job, so they're really losing money vs doing cash jobs. Thus, keep in mind their motivation here.]

To be fair, that is a valid assessment based on my observation as well, but I was already set on replacement. It's practically impossible to REALLY tell what condition a stress item like this is in, anyway.

Here's where it gets interesting. The letter we all received says that if the brackets were not installed properly, the axle replacement would be covered. So, thanks to the internet, I reviewed the previous document on how the brackets were supposed to be installed:

http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/ACM16933513/RCRIT-10V385-9203.pdf

Lo and behold, no expandable foam inside my bracket. So -- always being polite and appreciative -- I calmly asked Paul, my service advisor, to submit his photo of the small crack he found along with a note saying there was no expandable foam to Ford and see if they'd cover the entire replacement.

Guess what? Approved! I almost fell out of my seat when he called with the news.

So, the moral of the story is do your research. Nothing is guaranteed, but you'll want to review that doc above and see if YOU can find anything wrong with the installation. I had to pay $18 to replace the break pressure switch that was clearly leaking brake fluid, but due to my ignorance at the time, they got away with just putting the fusable link and handing it back to me. Luckily I learned that lesson in time. And, I think this makes up for that $18, eh?

Footnote: I recommend avoiding Gwinnett Place Ford for service to anyone in the Atlanta area based on that and one other little incident. When they did the front subframe recall, they *destroyed* the motor mounts and just acted dumb about it. I don't live around there anymore, but just thought I'd share anyway. (Their parts counter guys were friendly, though, and they actually discount the parts a little over list price, which is fairly unusual.)

Scubacat -

Thanks for sharing your experience. I haven't taken mine in yet.

Good catch on the foam: They put expanding foam inside the the ends of my axle during the first recall, so I won't have that one to fall back on.

I'm not sure how I'll proceed: Visually, my axle looks better than many I've seen - but my wife is making noise about liking recent Ford Fusion models, so putting money into the Windstar may not make sense for us.

yeah but it seems as soon as you cross the border the recalls just go un-noticed as i went to the dealer and had a recall check done and nothing turned up on their computer.... i can do a recall check online as well and nothing comes up and the notice that you guys posted is for U.S. dealerships what happened to Canadian dealerships.... oh maybe we are a little lax in our safety standards here...i am just getting frustrated with ford altogether as us has all kinds of recalls for these vans but in Canada nothing exists :banghead::banghead::banghead: