2002 Ford Windstar Problems

What owners report

Owners of the 2002 Ford Windstar most often describe two problems: a rear axle that cracks or breaks, frequently on vehicles whose recall repairs were already done, and persistent ABS/brake warning lights that come on with reduced or lost anti-lock braking. The axle complaints dominate the sample and are usually reported between roughly 90,000 and 200,000 miles, while brake-light complaints show up from about 55,000 miles upward. Corrosion-related subframe and control-arm damage also appears, often in vehicles registered outside the states covered by the corrosion recalls.

1. 1
   Suspension

   Rear axle cracks or breaks

   • 313 complaints (23%)
   • median 125,000 mi at 10.5 yrs old (282 state mileage)
   • 13 mention a crash, fire or injury
   • owner-quoted repair $850 (median of 30 quotes)
   • filed 2004–2025

   Complaints describe the rear axle cracking or breaking in half while driving, sometimes with a loud bang, smoke, or a tire rubbing the inner wheel well as the rear wheels tilt inward. Owners report loss of control, hard steering, and needing a tow, and several say the axle failed at or near the bracket installed during an earlier recall repair. Dealers and manufacturers are often described as saying the vehicle was not covered by a recall or that no open recall applied. Mostly reported between about 85,000 and 200,000 miles, often during ordinary driving or low-speed maneuvering.

   Recall 15V608000Recall 12V193000Recall 12V195000Recall 10V3850004 related service bulletins

   What to check: Have the rear axle inspected for cracks and corrosion, and ask for documentation of which recall campaigns were completed and when. Check for uneven rear tire wear or wheels that look tilted inward.

   2 excerpts from owner complaints in NHTSA records

   “2002 Ford Windstar; the rear axle broke in two while driving at 40 MPH. Both tires tilted out, axle cracked a little to the left of center while looking at it from the rear of the vehicle. Fortunately my wife was able to control the van. I understand this has happened in hundreds of windstars, and something needs to be done before people die, if they have not already.”

   NHTSA complaint #10331544, filed 2010-05, 112,000 miles

   “I was happy with Ford to this day. I have a 2002 Windstar that had its recall work done on the rear axle 2011. Like everyone that responded about this fix, it was a just to get you through till Ford was not responsible anymore. I happen to take the van into Ford for a coolant flush and they discovered the cracked axle right in the middle on the sleeve they installed. The wheel was tilted out. …”

   NHTSA complaint #10716854, filed 2015-05, 177,000 miles
2. 2
   Brakes

   ABS and brake warning lights, reduced braking

   • 771 complaints (57%)
   • median 98,000 mi at 8.7 yrs old (645 state mileage)
   • 36 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 64 quotes)
   • filed 2003–2025

   Owners describe the ABS and brake warning lights coming on intermittently and eventually staying on, often with longer stopping distances or the anti-lock function not working. Several complaints say a dealer or mechanic identified the ABS control module or its circuit board as the cause, and some report the lights returning after module repair or replacement. Reported from roughly 40,000 to 175,000 miles, with several owners noting the lights appear more often in hot weather.

   What to check: Verify that the ABS and brake lights go out after startup and stay out on a test drive, including after the van is warm. Ask whether the ABS module has been repaired or replaced and whether brake fluid level and leaks have been checked.

   2 excerpts from owner complaints in NHTSA records

   “Abs and brake light come illuminate on a daily basis. First noticed after hitting a bump on the highway about a year ago... Since then the light will come and go off at will. Occasionally there may be a sluggish feeling when in drive. I had it inspected but no one can tell me anything.”

   NHTSA complaint #10283612, filed 2009-09, 85,000 miles

   “After having a cruise control safety recall done on our 2002 Ford Windstar, the ABS light comes on and stays on most of the time now! I am assuming the ABS system is not working and we might have a safety issue when it comes to emergency braking situations.”

   NHTSA complaint #10339836, filed 2010-06, 125,000 miles
3. 3
   Body and structure

   Rear subframe and control-arm corrosion

   • 259 complaints (19%)
   • median 126,000 mi at 12.0 yrs old (225 state mileage)
   • 22 mention a crash, fire or injury
   • owner-quoted repair $800 (median of 15 quotes)
   • filed 2003–2026

   Complaints describe the front subframe, engine cradle, or lower control-arm mounting area rusting through and separating, sometimes with a loud pop followed by pulling, vibration, or loss of steering control. Owners report being told the vehicle was not covered by the corrosion recalls because of where it was registered, and several mention that recall parts were not available. Reported from about 60,000 to 160,000 miles, generally on older vehicles in rust-belt use.

   Recall 11V030000Recall 12V1940004 related service bulletins

   What to check: Have the subframe, cradle, and control-arm mounting points inspected on a lift for rust-through, and check whether recall 11S16 or related campaigns were performed.

   2 excerpts from owner complaints in NHTSA records

   “While driving we noticed a loud popping sound and the car pulled to the side. We stopped at a firestone and they showed me that the subframe had rusted through on the passenger side and the motor mount was completely broken loose. They recommended that we go to Ford. We took it to the Ford dealer and they said they knew of the problem but our minivan was not included in the recall because it is here in florida. I have serious problems with my spine and the doctor told me that a small accident could be fatal. …”

   NHTSA complaint #10404908, filed 2011-06, 72,384 miles

   “Backing out of the driveway there was a horrible sound, like the brakes sticking. Employee got out & the tire was cut completely around. The estimate is $900 to replace the springs & struts on both sides. I feel this is directly linked to the investigation & findings of the salt belt corrosion issues, but there is no recall for the specific components effected on the vehicle.”

   NHTSA complaint #10398230, filed 2011-04, 125,320 miles
4. 4
   Electrical system

   Stalling and electrical faults

   • 132 complaints (10%)
   • median 95,750 mi at 7.8 yrs old (114 state mileage)
   • 23 mention a crash, fire or injury
   • owner-quoted repair $888 (median of 7 quotes)
   • filed 2003–2026

   Owners describe the engine cutting off without warning while driving or in intersections, and instrument panel lights behaving erratically, including speedometer and fuel gauge failures. Some complaints mention a fractured ignition cylinder that prevents the key from turning, and one describes a melted ABS wiring harness. Mostly reported between about 90,000 and 170,000 miles.

   1 related service bulletin

   What to check: Ask about any history of stalling or no-start conditions, check that all warning lights and gauges work, and confirm the ignition key turns freely.

   2 excerpts from owner complaints in NHTSA records

   “We were driving down the road and the car randomly cuts off in the middle of the road sometimes it cuts off in the middle of a intersection causing us to almost get hit in the side of the car several times this has happend numorus times”

   NHTSA complaint #11343657, filed 2020-08, 166,000 miles

   “The contact owns a 2002 Ford Windstar. The contact stated that the harness connected to the anti-lock brake computer melted and caught on fire. The ABS warning light was illuminated on the instrument panel. Neither the dealer nor the manufacturer were notified of the failure. The vehicle was not repaired. The failure and current mileage was 115,000.”

   NHTSA complaint #10427230, filed 2011-09, 115,000 miles

Buying note. On this model year, the rear axle and subframe corrosion history is the main thing to verify: get the recall work documented and have the underside inspected before buying. Also confirm the ABS system is functioning, since warning lights that stay on are commonly reported.

Summary written with AI from a sample of 60 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.