The 1998 Ford Windstar is known for chronic transmission failures and rear axle fractures—two extremely expensive repairs that plague this generation. The 3.8L V6 also has significant head gasket and intake manifold leak issues.
AX4N/AX4S Transmission Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh or delayed 2-3 upshift, slipping in overdrive, Transmission overheating, burnt fluid smell, Complete loss of forward gears, limp mode, Whining or grinding noises during acceleration
Fix: The 4-speed automatic is fundamentally weak for this vehicle's weight. Oil cooler line failure contaminates fluid and accelerates clutch pack wear. Rebuild requires 12-16 hours; most shops recommend replacement with remanufactured unit due to core design flaws. External oil cooler retrofit is essential to prevent repeat failure.
Estimated cost: $2,200-3,800
Rear Axle Beam Fracture
Occasional · high severity
Typical onset: 90,000-150,000 mi
Symptoms: Clunking or popping from rear suspension over bumps, Visible rust or cracks near spring perches on axle beam, Rear end misalignment, uneven tire wear, In severe cases, catastrophic handling loss
Fix: Corrosion weakens the rear axle tube where coil springs mount, leading to stress fractures. Ford issued recalls but many slipped through. Requires complete rear axle assembly replacement (8-10 hours). Safety-critical—this can cause total rear suspension collapse.
Estimated cost: $1,200-2,000
Intake Manifold Gasket Failure (3.8L)
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust on cold start, Rough idle, misfires on multiple cylinders, Oil milkshake appearance on dipstick in severe cases
Fix: The composite lower intake manifold gaskets deteriorate and leak coolant internally. Requires manifold removal, gasket replacement, often includes upper plenum gaskets (6-8 hours). Check for coolant-contaminated oil before starting—may need oil flush.
Estimated cost: $800-1,400
Head Gasket Failure (3.0L and 3.8L)
Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Persistent overheating, bubbling coolant reservoir, Exhaust gases in cooling system (combustion leak test positive), External coolant seepage at head/block mating surface, Loss of compression in adjacent cylinders
Fix: More common on the 3.8L. Requires cylinder head removal, resurfacing, new gaskets, and bolt replacement (12-16 hours for both banks). Often discovers warped heads requiring machine work. Budget for head resurface ($150-250 per head) and inspect for cracked heads on the 3.8L.
Estimated cost: $1,800-3,200
Harmonic Balancer Separation
Occasional · medium severity
Typical onset: 90,000-130,000 mi
Symptoms: Severe vibration at idle that worsens with RPM, Visible wobble of crankshaft pulley, Squealing serpentine belt, repeated belt failures, Check engine light for crankshaft position sensor codes
Fix: The rubber damper ring separates from the hub, causing pulley wobble. Replacement requires balancer puller and installer tools (2-3 hours). Prolonged driving with failed balancer damages crankshaft keyway and front main seal. Replace serpentine belt at same time.
Estimated cost: $350-600
Front Coil Spring Fracture
Occasional · high severity
Symptoms: Clunking noise from front suspension over bumps, Vehicle sits lower on one front corner, Visible broken coil or rust perforation on spring, Tire rubbing on wheel well at full compression
Fix: Road salt corrosion causes spring fracture near the lower coil—subject to recall but not all were completed. Broken spring can puncture tire or damage fender liner. Replacement is straightforward with spring compressor (2-3 hours per side). Replace both fronts for even ride height.
Estimated cost: $400-700
Steering Sector Shaft Wear
Rare · medium severity
Typical onset: 120,000+ mi
Symptoms: Excessive play at steering wheel center position, Clunking when turning wheel from center, Wandering on highway, constant steering corrections, Fluid leak at steering box sector shaft seal
Fix: The steering gear sector shaft develops wear grooves, causing excessive lash. Requires steering gear replacement or rebuild (4-6 hours). Check for play before buying—difficult to adjust out. Alignment required after replacement.
Estimated cost: $600-1,100
Owner tips
Service the AX4N/AX4S transmission every 30,000 miles with Mercon V fluid and install an auxiliary transmission cooler—this is critical for longevity
Inspect the rear axle beam annually for rust perforation at spring perches, especially in salt states—catch this before it fractures
Replace intake manifold gaskets on the 3.8L proactively around 80,000 miles to prevent coolant intrusion into oil
Use a quality harmonic balancer (OEM or Dorman 594-104)—cheap parts fail quickly and damage the crankshaft
Check front coil springs for rust pitting during tire rotations—replace at first sign of corrosion
Avoid unless free—the combination of inevitable transmission failure and potential catastrophic rear axle fracture makes this one of Ford's most problematic minivans.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Be the first to unlock repairs for the 1998 Ford Windstar
Procedures haven't been generated for this vehicle yet. Become the founding sponsor and we'll generate expert-grade, step-by-step repair walkthroughs for every common job on it — free for every mechanic and DIYer who looks it up after, forever.
Ford Motor Company (Ford) is recalling certain model year 1998-2003 Windstar vehicles manufactured September 2, 1997, to July 3, 2003. The affected vehicles were previously remedied to safeguard against the rear axle cracking from corrosion, however, the remedy brackets may have been misinstalled. The incorrect bracket installations may limit the effectiveness of the service repair for NHTSA recalls 10V-385, 12V-193, and 12V-195.
Consequence: If the brackets were not installed properly, the rear axle may fracture, affecting the vehicle handling and increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will inspect the brackets to verify their proper installation. If a bracket is found to have been misinstalled, the rear axle will be replaced. These repairs will be performed free of charge. The began on October 21, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S27.
POWER TRAIN:AXLE ASSEMBLY · 12V193000
2012-05-03
FORD IS RECALLING CERTAIN MODEL YEAR 1998-2003 WINDSTAR VEHICLES MANUFACTURED FROM SEPTEMBER 1, 1997, THROUGH JULY 3, 2003, AND CURRENTLY REGISTERED OR ORIGINALLY SOLD IN VIRGINIA. OVER TIME,
CORROSION CAN WEAKEN THE REAR AXLE MAKING IT SUSCEPTIBLE TO TORSIONAL STRESS. CORROSION AND STRESS CAN LEAD TO CRACKS WHICH, IF UNDETECTED, CAN INCREASE AND RESULT IN A COMPLETE FRACTURE OF THE AXLE.
Consequence: A FRACTURED AXLE CAN AFFECT VEHICLE HANDLING AND INCREASE THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND INSTALL REAR AXLE REINFORCEMENT BRACKETS, OR REPLACE THE AXLES, AS NECESSARY. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE RECALL BEGAN ON JUNE 19, 2012. OWNERS MAY CONTACT FORD AT 1-866-436-7332.
FORD IS RECALLING CERTAIN MODEL YEAR 1998-2003 WINDSTAR VEHICLES MANUFACTURED FROM SEPTEMBER 1, 1997, THROUGH JULY 3, 2003, REGISTERED IN PUERTO RICO. DUE TO INCREASED STRESSES CAUSED BY HIGH CYCLES OF TORSIONAL LOADING, SPECIFIC TO THIS MARKET, THE REAR AXLE CAN CRACK.
Consequence: A FRACTURED AXLE MAY RESULT IN A LOSS OF VEHICLE CONTROL, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND INSTALL A REINFORCEMENT BRACKET ON THE REAR AXLE OR REPLACE THE AXLES, AS NECESSARY. THIS SERVICE WILL BE PROVIDED FREE OF CHARGE. THE RECALL BEGAN ON JUNE 1, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
FORD IS RECALLING CERTAIN MODEL YEAR 1998-2003 WINDSTAR VEHICLES MANUFACTURED FROM SEPTEMBER 1, 1997 THROUGH FEBRUARY 28, 2003 AND CURRENTLY REGISTERED OR ORIGINALLY SOLD IN CONNECTICUT, DELAWARE, 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. AFTER MANY YEARS OF VEHICLE SERVICE IN THESE AREAS, CORROSION CAN WEAKEN THE REAR AXLE, MAKING IT SUSCEPTIBLE TO TORSIONAL STRESS. CORROSION AND STRESS CAN LEAD TO CRACKS WHICH IF UNDETECTED CAN PROPAGATE AND RESULT IN A COMPLETE FRACTURE OF THE AXLE.
Consequence: A FRACTURED AXLE CAN AFFECT VEHICLE HANDLING AND INCREASE THE RISK OF A CRASH.
Remedy: AS PARTS BECOME AVAILABLE, DEALERS WILL INSPECT AND IF NECESSARY INSTALL THE REAR AXLE REINFORCEMENT BRACKETS FREE OF CHARGE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 20, 2010. OWNERS MAY CONTACT FORD AT 1-866-436-7332.
VEHICLE SPEED CONTROL · 09V399000
2009-10-13 · EA08021
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
SUSPENSION:FRONT:SPRINGS:COIL SPRINGS · 01I007000
2001-07-12 · EA00027
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1995-1998 FORD WINDSTAR MINIVANS. THE FRONT COIL SPRINGS COULD POTENTIALLY FRACTURE DUE TO CORROSION. NOTE: THE 1997-1998 WINDSTAR MINI VANS ARE ALSO COVERED BY NHTSA SAFETY RECALL 01V-199/FORD RECALL 01S19. THE MINI VANS COVERED BY THE SAFETY RECALL WERE ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, AND WISCONSIN, AND IN THE DISTRICT OF COLUMBIA.
Consequence: SOME TIRES HAVE DEFLATED DUE TO CONTACT WITH A BROKEN SPRING.
Remedy: FORD IS EXTENDING THE WARRANTY FOR FRONT COIL SPRING REPLACEMENT TO A TOTAL OF 10 YEARS OF SERVICE FROM THE WARRANTY START DATE, WITH UNLIMITED MILEAGE. THIS COVERAGE IS AUTOMATICALLY TRANSFERRED TO SUBSEQUENT OWNERS AT NO CHARGE. IF EITHER FRONT COIL SPRING FRACTURES DURING THE COVERAGE PERIOD NOTED ABOVE, THE DEALER WILL REPLACE BOTH SPRINGS AT NO CHARGE TO THE OWNER.
SUSPENSION:FRONT:SPRINGS:COIL SPRINGS · 01V199000
2001-06-18 · EA00027
ON CERTAIN MINIVANS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, AND WISCONSIN, AND IN THE DISTRICT OF COLUMBIA. THE FRONT COIL SPRINGS COULD FRACTURE AS A RESULT OF CORROSION. DEPENDING ON THE LOCATION OF THE FRACTURE, A BROKEN SPRING COULD MOVE PAST THE SPRING SEAT AND CONTACT A FRONT TIRE.
Consequence: SOME TIRES HAVE DEFLATED DUE TO CONTACT WITH A BROKEN SPRING.
Remedy: DEALERS WILL INSTALL PROTECTIVE SHIELDS AROUND THE FRONT COIL SPRINGS. OWNER NOTIFICATION BEGAN SEPTEMBER 6, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
EXTERIOR LIGHTING · 00V168000
2000-06-19
VEHICLE DESCRIPTION: MINI VANS, LIGHT PICKUP TRUCKS, AND SPORT UTILITY VEHICLES. OFF LEASE CANADIAN VEHICLES EQUIPPED WITH DAYTIME RUNNING LIGHTS WHICH MEET CANADIAN REQUIREMENTS AND NOT THE PHOTOMETRIC REQUIREMENTS OF FMVSS 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." ACCORDING TO FORD, THE VEHICLES WERE IMPORTED INTO THE U.S. ERRONEOUSLY.
Consequence: THE LIGHT GIVEN OFF FROM THE DAYTIME RUNNING LIGHTS IS BRIGHTER THAN ALLOWED BY U.S. STANDARDS.
Remedy: DEALERS WILL BE ADVISED TO DEACTIVATE THE RUNNING LIGHT FUNCTION AND TO COMPLETE ANY OUTSTANDING SAFETY RECALLS ON THESE VEHICLES.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 99V147000
1999-06-14
VEHICLE DESCRIPTION: MINIVANS. THE BRAKE FLUID MASTER CYLINDER IS RECESSED AND ORIENTED IN THE ENGINE COMPARTMENT SO THAT THE BRAKE FLUID WARNING STATEMENT EMBOSSED ON BOTH THE TOP OF THE FILLER CAP AND THE SIDE OF THE RESERVOIR BODY ARE NOT ENTIRELY VISIBLE BY DIRECT VIEW. THESE VEHICLES MAY NOT FULLY COMPLY WITH REQUIREMENTS OF FMVSS NO. 135, "PASSENGER CAR BRAKE SYSTEMS."
Remedy: OWNERS WILL BE PROVIDED WITH NEW LABELS AND INSTALLATION INSTRUCTIONS.
STRUCTURE:BODY · 99I001000
1999-06-02 · SQ99001
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: MINIVANS. THE OVERHEAD CONSOLE REAR RETAINING BRACKET CAN DEVELOP CRACKS AND SEPARATE, ALLOWING THE OVERHEAD CONSOLE TO BECOME LOOSE AND POSSIBLY FALL DOWN.
Consequence: IF THE CONSOLE DOES FALL DOWN, IT COULD DISTRACT THE DRIVER OR POSSIBLY STRIKE A FRONT SEAT OCCUPANT.
Remedy: DEALERS WILL INSTALL A REDESIGNED RETAINING BRACKET IN THE SAME LOCATION AS THE ORIGINAL RETAINING BRACKET.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER · 98I003000
1998-07-30 · EA98008
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. MINI VANS SOLD DURING THE MONTHS OF DECEMBER 1996, AND JANUARY, FEBRUARY AND MAY 1997. FRONT BRAKE CALIPER ANCHOR PLATE TO HUB AND SPINDLE ASSEMBLY BOLTS MAY BE LOOSE AS A RESULT OF AN INCOMPLETE TIGHTENING OPERATION AT THE ASSEMBLY PLANT.
Consequence: WHEN THE BOLTS ARE LOOSE, A NOTICEABLE NOISE AND/OR VIBRATION IS EVIDENT WHICH PROVIDES WARNING TO THE VEHICLE DRIVER. VEHICLE BRAKING IS NOT DEGRADED.
Remedy: DEALERS WILL TIGHTEN THE FRONT BRAKE CALPIER ANCHOR PLATE BOLTS. OWNERS CAN CONTACT FORD AT 1-800-392-3673.
STEERING:GEAR BOX:SHAFT SECTOR · 97V165000
1997-09-30
VEHICLE DESCRIPTION: PASSENGER VEHICLES AND MINI-VANS. THE RACK AND PINION STEERING GEARS MAY HAVE DAMAGED INPUT SHAFT BEARINGS.
Consequence: THIS CONDITION CAN INCREASE STEERING EFFORTS, AFFECTING STEERING CONTROL.
Remedy: DEALERS WILL INSPECT THE DATE CODE ON THE RACK AND PINION STEERING GEAR, AND, IF NECESSARY, REPLACE THOSE RACK AND PINION ASSEMBLIES THAT FALL WITHIN THE SUSPECT DATE CODE RANGE. THE DATE CODES FOR WINDSTAR MODEL VEHICLES ARE
97JB09 OR 97JC08; THE DATE CODES FOR MUSTANG MODEL VEHICLES ARE 97J09B OR
97J08B.
POWER TRAIN:AUTOMATIC TRANSMISSION · 97V097000
1997-06-09
VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH AX4S AUTOMATIC TRANSAXLES. THE LOW/INTERMEDIATE SERVO COVER CAN SEPARATE FROM THE TRANSAXLE WHILE THE VEHICLE IS BEING DRIVEN. IF THIS OCCURS, TRANSMISSION FLUID WILL LEAK CONTACTING THE CATALYTIC CONVERTER.
Consequence: THE CATALYTIC CONVERTER TEMPERATURE MAY BE HOT ENOUGH TO IGNITE THE TRANSMISSION FLUID AND CAUSE A VEHICLE FIRE.
Remedy: DEALERS WILL INSPECT THE TRANSMISSION AND REPLACE THESE SERVO COVERS.
CHILD SEAT · 97V051000
1997-04-01
VEHICLE DESCRIPTION: MINIVAN EQUIPPED WITH SECOND ROW BENCH SEATS WITH OPTIONAL INTEGRATED CHILD SEAT (ICS). THE HEADREST LOCKOUT MECHANISM ON THE SEATS MAY NOT ENGAGE AND LOCK THE HEADRESTS IN THE "DOWN" POSITION, AS INTENDED, WHEN THE ICS IS DEPLOYED. A VEHICLE OCCUPANT COULD MOVE THE HEADREST TO THE "UP" POSITION.
Consequence: AS A RESULT OF THE HEADREST BEING IN THE "UP" POSITION, A CHILD SEATED IN THE ICS WOULD RECEIVE LESS THAN THE INTENDED PROTECTION IN THE CHILD HEAD AREA IN THE EVENT OF A CRASH.
Remedy: THE SECOND ROW BENCH SEATS HAVE BEEN REPLACED WITH SEATS BUILT WITH REVISED HEADREST LOCKOUT MECHANISMS.
Building an app?
Free API access to all this data — 50 requests/day, no card required.