NHTSA expands Ford Windstar corrosion probe to front subframes

[tebo77]

Thanks, Phil!

[Off_Timing]

Well, the wife just called. The Ford stealership told her the rear axle and subframe are intact. They're going ahead and installing the band-aids. The stealership went on to say that the front brakes need to be replaced, $500. We told them to go ahead with the recall fixes, but the brake job gets done at my "trusted" mechanic.

So, it looks like out Winnie is going to carrying an extra few pounds for all that extra iron they're adding to the axle and subframe.

[jerryt1999]

My winstar in for recall. i have already replaced rear axle. my subframe at right rear was split and i understand that bandaid bracket is ok. i let dealer know my subframe started rusting on left side ahead of lower control arm mount and i welded it. They stated that the subframe meets recall guidelines for repair. Any thoughts?

[Windstartled]

Originally Posted by jerryt1999

i let dealer know my subframe started rusting on left side ahead of lower control arm mount and i welded it. They stated that the subframe meets recall guidelines for repair. Any thoughts?

I would let 'em (re)fix it, quality of the work will be Ford's responsibility not just yours. And it's free to boot.

[eroosa]

Well I got the call from the dealership that the van was fixed (sub frame brackets) and then I was told that it would not pass inspection in NYS for it was showing a misfire code. That is a no brainer for the van with wonderful ethanol blended gas sat for three months from freezing cold to very hot temps. I ran the crappy old gas out, cleared the codes and got 110 miles on it and now it is running like crap again and I got the check engine light on it again. Nice. I can't get it inspected with this situation and Ford and the Dealership say that this is nothing that is covered. I spent an hour on the phone with Ford and was told the same thing. Any suggestions on a fix? I ran it down to almost empty. It actually started running fine when I got down to a quarter of a tank. Then I filled it up with fresh gas from a busy gas station with 87 octane, put two bottles of octane boost to treat 30 gallons and a can of sea foam. It ran fine for about 60 miles and now it is running like crap. Should I change the fuel filter? It was new last summer, but I am thinking it is full of crap now. Why would the van run good as it was running below 1/8 tank and then start running like crap again after I filled it up as described above?
Thanks,
Ed

[tebo77]

What brand gas? It may not make a difference since you used additive, but I know my Windstar only liked Mobil gas...no idea why but it would run like crap with anything else.

[eroosa]

Brand of gas has never mattered. Just sitting three months did. I just picked up a fuel filter. It is worth it to try replacing it anyway.

[charkettes]

1999 Windstar SEL, 54,524 miles-sub-frame rusted through on sway bar mount.
After last recall, 11S16 Front sub-frame, lower control arm at end of May 2011, there was noise in turning right. June 3, I went back to dealer and he told me the above!!! I was shocked and they said that it was not part of the recall and they could get a used one once done with investigating. Ford manufactured new ones that cost $2,200.00 but will only give to warranty customer. Now who has a warranty from 1999? They could get me a used one that would come in a week and the cost of it plus labor and taxes would be around $1,500.00!!! I have been out of work since Oct 2009 and looking for work but I am a little afraid each time I drive to an interview because this is a safety issue. I have complained to safercar.gov as well as other places. I have written Ford Motor Corp. and no one seems to want to do anything about this safety issue because I live in the "salt-belt". Does anyone have any suggestions?

[Windywoes]

I took my '99 Windy to local Ford dealer for inspection of sub frame & rear axle. My sub frame was so badly rusted that I could no longer drive it. Rear axle looked good to me. Ford says Sub frame will be replaced NC and rear axle is OK. Since this van is not worth much money-wise I will be glad to get it back as it runs well. It does have some electrical issues like gauges going crazy and no rear right brake light. Probably a bad ground or more rust.

[phil-l]

Beware of rear axles that "look" good: As I understand it, the failure starts with a very small crack that grows quickly.

The rear brake light assemblies are actually pretty well protected from corrosion (I'm familiar with mine as the result of a trailer hookup wiring project). It's a straightforward job to remove the light assembly and check the wiring.