1995 Ford Windstar Problems

What owners report

Owners of this model year most often report engine and cooling problems, above all head gasket and timing cover gasket failures that let coolant into the engine, usually at relatively low mileage and sometimes with little warning. Transmission complaints are the next most common, describing harsh or delayed shifting, slipping and fluid leaks, and a separate group of complaints covers brake line corrosion, cracked fuel tanks and broken front suspension parts as these vans age.

1. 1
   Engine cooling

   Head gasket and coolant leak leading to engine trouble

   • 1,263 complaints (38%)
   • median 78,330 mi at 8.5 yrs old (93 state mileage)
   • 14 mention a crash, fire or injury
   • owner-quoted repair $1,788 (median of 200 quotes)
   • filed 1995–2010

   Owners describe the engine running rough, misfiring, idling high, blowing white or black smoke from the tailpipe, losing heat from the heater, or overheating; several had coolant leaking from the timing cover and later found low compression. Complaints say repair shops and dealers diagnosed a failed head gasket, sometimes recommending a replacement engine, and some owners report the same failure returning after a previous repair or replacement engine. Several mention a Ford extended coverage program for the head gasket and say the repair was declined because the time or mileage limit had passed. Reported from roughly 15,000 to over 175,000 miles, with many complaints in the 55,000-130,000 mile range and no consistent warning beforehand.

   What to check: Check the coolant level and look for coolant seeping near the timing cover, and ask for any head gasket or engine replacement records with dates and mileage. A coolant pressure test and a look at the oil and tailpipe smoke on a cold start can help before purchase.

   2 excerpts from owner complaints in NHTSA records

   “1995 Windstar with 3.8v6. Head gasket leak. Have researched online and came across scores of this problem and have seen that many of these issue were reolved at no charge because it is a manufacturing defect. I am wondering if this is so and how do I present this to the Ford repair people. Thank you for your time and consideration sincerely, james haugh.”

   NHTSA complaint #10090793, filed 2004-09, 65,000 miles

   “1995 Ford winstar head gaskets leaking. Head gaskets were replaced mar 1999 at 40352 mi. Under 98m01 recall. And again jul 2001 at 79464 mi. Under 00m09 recall. Talked to my local Ford dealer, they said to call dealer that did repair. Both said there was nothing they could do for me. But head gaskets should last more than the 9246 mi. Said repair warrenty only good for 12 months.”

   NHTSA complaint #10070343, filed 2004-01, 88,750 miles
2. 2
   Transmission and drivetrain

   Harsh, delayed or slipping transmission

   • 531 complaints (16%)
   • median 97,802 mi at 8.9 yrs old (39 state mileage)
   • 18 mention a crash, fire or injury
   • owner-quoted repair $1,688 (median of 71 quotes)
   • filed 1995–2015

   Owners report the van hesitating between gears, shifting hard or lurching into gear, slipping at stop lights, and in some cases fluid leaking out or metal debris found in the pan. Some complaints describe a transmission that failed at low mileage and was replaced, occasionally more than once, while others say dealers adjusted shift points and reported no fault before an independent shop rebuilt the unit. Owners also link transmission fluid leaks to smoke and, in one complaint, to a fire. Reported from around 36,000 to 180,000 miles, often between 70,000 and 130,000 miles.

   What to check: Check the transmission fluid level and colour and look for leaks or residue under the van, and test-drive through gear changes including reverse. Ask about rebuilds or replacements and keep the receipts.

   2 excerpts from owner complaints in NHTSA records

   “Overdrive light starts flashing and does not go into gears as it should. Also have recently had to replace struts--broke as I was driving along. Had to replace rear axle already and have been told my year of Windstar was not included in recall.”

   NHTSA complaint #10375441, filed 2011-01, 175,250 miles

   “Transmission failed on 5/30/02 on our 1995 Ford Windstar when mileage was 78,476. Cost of new transmission was $2732.92. Previously we had replaced transmission in 8/00 when mileage was 61,210.”

   NHTSA complaint #10010278, filed 2003-03, 78,476 miles
3. 3
   Brakes

   Corroded brake lines and brake fluid leaks

   • 431 complaints (13%)
   • median 116,000 mi at 11.1 yrs old (45 state mileage)
   • 61 mention a crash, fire or injury
   • owner-quoted repair $1,400 (median of 26 quotes)
   • filed 1995–2013

   Complaints describe brake lines rusting through, in some cases spraying fluid onto the catalytic converter or producing smoke, and a brake pedal that went to the floor. Owners report the front lines repaired under a recall while the rear lines were found corroded and not covered, and some say the pedal pulsated or stopping distance increased. One owner reports ABS problems after recall work was performed. Mostly reported from about 66,000 to 175,000 miles, with several complaints past 100,000 miles on older vehicles.

   Recall 02V101000

   What to check: Have the brake lines inspected along their full length, especially above the catalytic converter and at the rear, and ask whether the brake line recall was done. Check the fluid level and look for leaks or damp spots at the wheels and lines.

   2 excerpts from owner complaints in NHTSA records

   “At 146,00 miles I was just informed that I will have to have another head gasket repair done (that would make it the third time this part has failed) to save the car...I will not do it, as in february, I spent over $750 to have the rear brakes repaired for brake fluid covering the shoes of the brakes, cause by brake line corrosion (just as in the right front brake line corrosion that was a national recall!!!!) but there was no recall for the rears”

   NHTSA complaint #10070152, filed 2004-01, 146,000 miles

   “Check engine light kept coming on our 1995 Ford Windstar van. Also, the anti brake lock system kept trying to incorrectly engage. When taken into the local Ford dealer we were told that we had 3 bad sensors. Two brake sensor and 1 check engine sensor were faulty and would need replaced. We were told the worse case scenario was the brakes would wear out due to the anti lock mechanism trying to engage and the van my stall due to the other faulty sensor. We were also told these sensor are replaced often. …”

   NHTSA complaint #10161168, filed 2006-06, 104,832 miles
4. 4
   Fuel system

   Cracked fuel tank and fuel smell

   Mentioned in 9 of 80 sampled complaints

   Owners describe a strong gasoline smell after filling up, wet stains or fuel running onto the ground from the driver side, and a crack in the tank near the forward mounting strap. Complaints say the tank was replaced by a shop or dealer, and some owners report the regional tank recall did not cover their vehicle or that replacement tanks were hard to obtain. Reported from about 65,000 to 270,000 miles, frequently noticed right after refuelling, with several complaints in hot-weather states.

   Recall 99V309000

   What to check: Smell around the tank after a fill-up and look for damp or stained areas near the front tank strap, and ask whether the fuel tank has been replaced and under which program.

   2 excerpts from owner complaints in NHTSA records

   “My fuel tank developed a crack and began leaking. The tank was replaced by the dealer. I contacted the dealer about a recall (99r33). The dealer says replacement of the tank is not included in this recall. I have contacted Ford to get clarification since their website says I am included when I enter my VIN number into their recall search feature.”

   NHTSA complaint #10031092, filed 2003-08, 96,000 miles

   “Fuel tank began leaking and had to be replaced. The Ford website shows that my car is subject to recall 99r33, faulty fuel tank mounting. This is a regional recall for southern states with high temperature. I am in tennessee and was not included in the recall notification system, although tennessee has high temperaturtes like alabama that is included and I have vacationed each summer in alabama.”

   NHTSA complaint #10070728, filed 2004-01, 96,020 miles
5. 5
   Suspension

   Broken front coil springs and stabilizer bar

   Mentioned in 6 of 80 sampled complaints

   Complaints describe cracked front coil springs and a front stabilizer bar that broke in two, with owners reporting wandering steering, body roll or pulling. Some owners found a recall covering front coil springs but say their vehicle was not included or the free repair period had expired; the stabilizer bar was replaced with a solid design in one case. Mostly reported between about 125,000 and 235,000 miles on older vehicles.

   What to check: Have the front springs and stabilizer bar inspected for cracks and corrosion, and ask whether any spring recall work was performed or is still open for the VIN.

   2 excerpts from owner complaints in NHTSA records

   “I own a 1995 Ford Windstar the paint is blistering off in huge pieces. Ford says it is not their problem , paint should not peal from a car like this it is blistering off in sheets . I have read that Ford is paying for painting only if the customers are really loud about complaints. I have also read that many complaints have already been sent here. This automobile has been a nightmare with defects and recalls. Anyone in the automotive business laughs when they here what kind of car I own. …”

   NHTSA complaint #10063888, filed 2004-03, 36,000 miles

   “1)my van was pulling to the right and the tires were worn. 2) I took my 1995 Ford Windstar to firestone to have new tires put on and an alignment done. They installed the tires and told me they could not do the alignment because the sway bar was broken in two. They also stated it was bad craftsmanship because the bar is a hollow metal tube instead of a solid piece. They also said I needed both inner tie rod ends replaced because the lack of control from the sway bar put stress on them and damaged them. …”

   NHTSA complaint #10164450, filed 2006-08, 132,950 miles

Buying note. These vans are now old enough that maintenance history matters more than mileage; ask for records of head gasket, transmission, brake line and fuel tank work, and have any candidate inspected for coolant leaks, rusted brake lines and cracked springs before buying.

Summary written with AI from a sample of 80 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.