Broken Coil Spring

[lewisnc100]

Had a bad metal banging noise coming from the rear end but no real difference in the ride, traced the noise to the right rear. Went under the car with a rubber mallet and checked everywhere, no noise and all components tight. Finally heard the noise by hitting the rear tire lightly with the mallet, had my wife hit it while I searched. Ended up the top few coils of the coil spring had broken off and fallen straight down to the lower perch, then sideways into the axle tube. So every bump this small coil was banging around inside the axle tube making a huge racket. Luckily the coil spring broke just at the top flat part rather than in the middle somewhere so the ride was still about the same.

Unfortunately my family is heading to SC for vacation this Friday so its going to be a quick repair this week. I'm assuming I should change both coil springs, only 1 is broke but I want to keep the ride consistent on both sides. I'll also plan on replacing both rear shocks since I have to unbolt them to get the springs out. Any recommendations on shocks?

Is it just me or is breaking a coil spring at under 60k miles a little worrying? Well at least it wasn't at high speed heading down the highway.

[garync1]

It could have been a factory defect. Or someone could have caught a hard curb, may have forgot. Monrore or any of the after markets they make for the Winstar are good. yea you may want to do both sides, its not a have too, but maybe a want to.You may or may not notice a difference.You may have to get the springs from the factory not sure if some auto parts will stock may have to order. The shocks and or strut asembley are normally in stock.

[lewisnc100]

Originally Posted by garync1

You may have to get the springs from the factory not sure if some auto parts will stock may have to order.

That's what I'm finding out this morning, that no Ford dealerships stock these springs. Plus I've found out that on any given 2000 Windstar there were 4 types of rear coil springs, you have to look for the number on the spring itself to order replacements. It's not a part number, they called it an engineering number. Luckily mine still had a tag on the spring with the number. It's going to be tight to see if I can get them in this week in time to replace them before my trip.

[ModMech]

There is a RECALL on this concern, should be repaired by the dealer at NO COST.

I will check to see if I can find the campain number.

[lewisnc100]

Originally Posted by ModMech

There is a RECALL on this concern, should be repaired by the dealer at NO COST.

I will check to see if I can find the campain number.

Thanks for checking, I saw one for the front coils but not the rear.

[garync1]

IF you do order the springs from the dealer and you run short on time doing one want really hurt anything just change out the other side when you come back from the trip.You may not notice any difference. Can't seem to recall if the winstar calls for a 4 wheel aliagnment but that would be a good idea on any suspension swap.

[lewisnc100]

I checked again and it looks like the recalls were for the front coil springs on the Windstars up until the 98 model year, coil springs could break and blow the front tire.

Anyway the dealership got the new springs in yesterday morning and I got the new springs and shocks (Gabriel Ultras) installed last night. Very surprised how easy this was on the Windstar, I'm used to rusted bolts, long breaker bars and lots of penetrating oil on suspensions. But the Windstar was easy, had everything swapped in a little over an hour with most of that time being jack work.

If anyone else replaces the coil springs on a 99+ Windstar note that springs have changed. I called 3 dealerships and only 1 seemed to know that my original springs had been replaced by a new part, the other 2 wanted to order the same original spring directly from the manufacturer. My OEM springs were about 1/2" diameter coils but at the top and bottom ends the diameter of the coils tapered to around 3/8" diameter for the last couple of loops. That 3/8" diameter section is what broke on the top of my original spring. The new springs stay at 1/2" diameter coils throughout the spring.

[garync1]

I know you did not do all four but let me know how you like the Gabriel Ultras.

[fcrew]

The Windstar does not need a 4 wheel alignment(rear axle is non-adjustable).