This is a serious problem, if you own a 1999-2003 Ford Windstar please read on. In May of 2010, the NHTSA opened an investigation evaluation into broken rear axles on the 1999–2003 Ford Windstars. At the time, they said to have received 234 complaints, including two reports of accidents. CarComplaints.com meanwhile had received a total of 211 complaints for the following model years: 1999 (30 complaints), 2000 (78 complaints), 2001 (80 complaints), 2002 (20 complaints), 2003 (2 complaints).

How This Happens and Common Risk Factors

According to many mechanics, these failed axles are due to corrosion. Windstars have a piece of sheet metal molded around the axle and apparently there's no way for the moisture to escape. And when salt spread on roads in winter gets in, that leads to the corrosion. In fact, according to the NHTSA evaluation document, this problem seems to be much worse in states that use a lot of road salt.

“The rear axle beam in the subject vehicles is an inverted ‘U’ channel design, which appears to provide a collection point for road salt slurry, resulting in corrosion that progressively weakens the part until it fractures,”

Since the Windstar is a front-drive vehicle, breaking a rear axle isn't critical as it could be; at least that's the position taken by Ford, with a spokesman telling the New York Times that the driver remains in control of the car at all times. While somewhat true, this still doesn't reduce the danger of this problem with many owners telling horror stories of their axles breaking while driving highway speeds.

1. Cracked Rear Axle 2001 Ford Windstar
2. Rear Axle Failure 2000 Ford Windstar

The Windstar Rear Axle Recall

On Friday, August 27th, Ford announced a voluntary recall of 575,000 1998-2003 Windstar minivans because of rear axles rusting. According to the official press release by Ford:

Ford is voluntarily recalling older, high-mileage Windstar minivans produced between mid-1997 and early 2003 for rear axles ... We will notify affected owners in the very near future and ask them to bring their vehicles to their local dealers for inspection and any necessary repairs.

Ford dealers at no charge to customers will reinforce the axles of the affected vehicles as parts are available. If it's determined the axle can't be reinforced, it will be replaced as soon as parts are available. Ford will provide for rental vehicles for customers until the rear axle of their vehicle has been replaced.

The initial axle recall notice covered Windstars manufactured at Ford's Oakville Assembly Plant (Ontario, Canada) from 9/1/1997 through 2/28/2003, sold in in the so-called "salt belt" states: 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, Vermont, West Virginia and Wisconsin.

Under pressure from the Center for Auto Safety, Ford announced on November 30th that the recall had been extended to cover Windstars built through July 3 2003. Ford also added Utah to the list of covered states.

This rear axle issue is the eleventh recall for the Windstar, a model that was only built for a total of nine years.

What Owners Are Saying

“While driving the 2001 Windstar the vehicle began to feel as if it was swaying side to side. Upon feeling this we stopped driving the vehicle at once. I thought it might be a suspension problem. Not so. After taking the vehicle to the shop we were informed that our axle was 3/4 cracked and needed a replacement. We found one used and had it installed. I can't imagine what would happen if this broke driving down the highway. We have 3 kids with us all the time and can't be driving around with problems like this. I think FORD needs to recall this vehicle and fix the problem.”

Greg P., Evergreen Park, IL

“After having another problem fixed on my Windstar, I did a generaL search on the web looking for recalls etc. I came across Autobeef and read about the other unfortunate owners of Windstars that had the rear axle break on them. I figured it was probably a rare problem so I really didn't pay too much attention to it. The next day I started hearing a metallic cracking sound each time I took a sharp right hand turn in the Windstar. I parked the car, crawled under and found a 2 inch crack in my axle!! $785 dollars later I have a new axle in the car and the car is safe...for now. Also register a complaint with Ford. Not expecting to get much of a response from them. Thank you Autobeef. If It wasn't for this website, I would have never thought to check the axle for problems!”

billbug, Springfield, MA

Worst Years for the rear axle failure

See the links below for more information on the Windstar model years with the most axle complaints:

• 2003 Ford Windstar axle problems
• 2002 Ford Windstar axle problems
• 2001 Ford Windstar axle problems
• 2000 Ford Windstar axle problems
• 1999 Ford Windstar axle problems

Have Your Say

Let us know if you've experienced this problem, know of a potential fix or just want to voice how frustrated you are: