The 1999 Ford Windstar is infamous for catastrophic transmission failures and head gasket issues, particularly on the 3.8L V6. These vans had their moments, but the drivetrain reliability issues overshadow most positives.
AX4S/AX4N Automatic Transmission Failure
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Harsh or delayed shifting between gears, especially 2nd to 3rd, Slipping under acceleration or complete loss of forward gears, Whining or grinding noises from transmission, Burnt transmission fluid smell, dark or metallic fluid on dipstick
Fix: The 4-speed automatic is notoriously weak in these vans. Internal clutch packs and planetary gearsets fail. Rebuild runs 12-16 hours labor, but many shops won't touch them due to high re-failure rates. Remanufactured unit swap is more reliable. Transmission cooler lines frequently leak or clog, accelerating failure.
Estimated cost: $2,200-3,800
3.8L V6 Head Gasket Failure
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: White smoke from exhaust, especially on cold start, Coolant loss with no visible external leaks, Overheating or fluctuating temperature gauge, Milky oil on dipstick or oil cap, rough idle
Fix: The 3.8L Essex engine has weak head gasket design prone to coolant seepage into cylinders. Requires both heads removed, resurfaced if warped (common), new gaskets, and timing chain/guide inspection. 14-18 hours labor. The 3.0L Vulcan is significantly more reliable in this regard.
Estimated cost: $1,800-2,800
Rear Axle Corrosion and Bearing Failure
Occasional · high severity
Typical onset: 100,000-180,000 mi
Symptoms: Grinding, humming, or howling noise from rear that changes with speed, Visible rust perforation around rear axle mounting points, Clunking on acceleration or deceleration, Rear end sag or uneven ride height
Fix: Rear axle beam and mounting brackets rust through in salt states, leading to structural failure (multiple recalls). Wheel bearings pressed into the beam also fail. Full axle assembly replacement is 4-6 hours. Inspect thoroughly on any used purchase—this is a safety-critical failure that can cause wheel separation.
Estimated cost: $800-1,500
Intake Manifold Gasket Leak (3.8L)
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Coolant puddle under front of engine, especially after overnight, Rough idle or hesitation, possible misfire codes, Sweet coolant smell from engine bay, Gradual coolant loss requiring frequent top-offs
Fix: Plastic intake manifold develops cracks, and lower gaskets fail allowing coolant into oil or external leaks. Manifold removal required, 5-7 hours labor. Often done alongside thermostat and hoses. Can cause engine damage if ignored and run low on coolant.
Estimated cost: $600-1,100
Suspension Control Arm Bushing Failure
Occasional · medium severity
Typical onset: 80,000-140,000 mi
Symptoms: Clunking over bumps from front end, Steering wander or loose feeling at highway speeds, Uneven tire wear on inside or outside edges, Vehicle pulls to one side after hitting bumps
Fix: Front lower control arm bushings deteriorate, causing alignment shift and handling issues. Recall addressed some front control arm failures. Replacement requires pressing new bushings or installing complete control arms. 3-4 hours for both sides, alignment mandatory after.
Estimated cost: $500-850
Harmonic Balancer Failure
Occasional · medium severity
Typical onset: 100,000-160,000 mi
Symptoms: Severe vibration at idle that smooths out at higher RPM, Visible wobble of crankshaft pulley when engine running, Serpentine belt wear or repeated belt failures, Squealing or chirping from front of engine
Fix: Rubber isolator in harmonic balancer separates, causing crankshaft pulley to wobble. Can damage crankshaft nose or trigger timing chain issues if the balancer comes apart. Replacement is 2-3 hours, requires special puller tool. Not uncommon to find balancer bolts loose or missing.
Estimated cost: $350-600
Owner tips
Change transmission fluid every 30k miles with Mercon V—most failures stem from neglected fluid that overheats
The 3.0L Vulcan V6 is far more durable than the 3.8L—seek out that engine if buying used
Budget $500/year minimum for unexpected repairs after 100k miles; these vans nickel-and-dime you to death
Hard pass unless free or under $1,500—transmission and head gasket issues make this a money pit that's not worth the gamble, even for a beater.
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.
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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.
SUSPENSION:FRONT:CONTROL ARM · 12V194000
2012-05-03
FORD IS RECALLING CERTAIN MODEL YEAR 1999-2003 WINDSTAR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATE OF VIRGINIA. CORROSION-RELATED FRACTURES OF THE FRONT LOWER CONTROL ARM REAR ATTACHING BRACKETS AND BODY MOUNT ATTACHMENTS MAY OCCUR.
Consequence: A SEPARATION OF A FRONT LOWER CONTROL ARM REAR ATTACHING BRACKET MAY RESULT IN A LOWER CONTROL ARM SEPARATION. A SEPARATION OF BOTH FRONT SUBFRAME REAR BODY MOUNTS MAY RESULT IN SEPARATION OF THE STEERING INTERMEDIATE SHAFT.
EITHER CONDITION COULD RESULT IN SIGNIFICANT LOSS OF STEERING CONTROL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT BOTH FRONT LOWER CONTROL ARM REAR ATTACHING BRACKETS AND BOTH BODY MOUNT ATTACHMENTS AT THE REAR OF THE FRONT SUBFRAME AND MAKE THE NECESSARY REPAIRS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 18, 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.
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS · 11V030000
2011-01-26 · EA10007
FORD IS RECALLING CERTAIN MODEL YEAR 1999-2003 WINDSTAR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF 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, UTAH, VERMONT, WEST VIRGINIA, AND WISCONSIN. A SEPARATION OF A FRONT LOWER CONTROL ARM REAR ATTACHING BRACKET MAY RESULT IN A LOWER CONTROL ARM SEPARATION. A SEPARATION OF BOTH FRONT SUBFRAME REAR BODY MOUNTS MAY RESULT IN SEPARATION OF THE STEERING INTERMEDIATE SHAFT.
Consequence: THIS COULD RESULT IN REDUCED STEERING CONTROL INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT BOTH FRONT LOWER CONTROL ARM REAR ATTACHING BRACKETS, AND BOTH BODY MOUNT ATTACHMENTS AT THE REAR OF THE FRONT SUBFRAME, AND MAKE THE NECESSARY REPAIRS FREE OF CHARGE. IF REPAIRS CANNOT BE MADE TO A VEHICLE, FORD WILL OFFER TO REPURCHASE THE VEHICLE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 21, 2011. 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 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.
FUEL SYSTEM, GASOLINE · 06E056000
2006-06-13
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Consequence: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
VEHICLE DESCRIPTION: MINI VANS. CONTAMINANTS SUCH AS WATER, SALT, AND WINDSHIELD WASHER SOLUTION CAN ENTER THE WIPER MOTOR COVER ASSEMBLY THROUGH PINHOLES ON THE EXTERIOR OF THE COVER THAT ARE USED IN THE MOLDING PROCESS. IN ADDITION, ON CERTAIN OF THE VEHICLES BUILT BETWEEN FEBRUARY AND AUGUST 2000, A SWITCH LOCATED IN THE PLASTIC COVER OF THE WIPER MOTOR GEAR CASE COULD MALFUNCTION AND OVERHEAT. EITHER OF THESE CONDITIONS COULD POTENTIALLY RESULT IN LOSS OF INTERMITTENT WIPER FUNCTION, LOSS OF WIPER PARK FUNCTION, COMPLETE LOSS OF WIPER FUNCTION, SMOKE, OR IGNITION OF THE PLASTIC COVER MATERIAL. CONTAMINANT ENTRY COULD ALSO RESULT IN UNINTENDED WIPER MOTOR OPERATION.
Consequence: SWITCH MALFUNCTION IS MOST LIKELY TO OCCUR WHEN THE INTERMITTENT SETTING OF THE WIPERS IS BEING USED, OR WHEN SNOW OR ICE OBSTRUCTS THE BLADES FROM RETURNING TO THE "PARKED" POSITION AT THE BOTTOM OF THE WINDSHIELD. LOSS OF VISIBILITY WHILE DRIVING INCREASES THE RISK OF A CRASH.
Remedy: DEALERS WILL INSTALL A NEW WIPER COVER WITH IMPROVED SEALING AND WATER RESISTANCE. OWNER NOTIFICATION BEGAIN AUGUST 27, 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 1-866-436-7332.
EQUIPMENT:APPLIANCE:AIR CONDITIONER · 01V262000
2001-08-15
VEHICLE DESCRIPTION: MINI VANS EQUIPPED WITH AUXILIARY REAR AIR-CONDITIONING. IF THE AUXILIARY AIR-CONDITIONING BLOWER MOTOR STOPS TURNING WHILE IN THE MEDIUM-LOW BLOWER SPEED SETTING, THERE IS THE POTENTIAL THAT THE RESISTOR MAY BECOME HOT AND SMOKE.
Consequence: THE MOTOR COULD POTENTIALLY CATCH ON FIRE.
Remedy: DEALERS WILL INSTALL A JUMPER WIRE THAT WILL ENSURE THAT THE MEDIUM-LOW BLOWER SPEED SETTING IS PROTECTED BY THE THERMAL LIMITER. OWNER NOTIFICATION BEGAN AUGSUT 27, 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 1-866-436-7332.
VEHICLE DESCRIPTION: MINIVANS BUILT WITH INSTRUMENT CLUSTERS WITHOUT THE MESSAGE CENTER, FAIL TO COMPLY WITH THE REQUIREMENTS OF STANDARD NO. 118, "POWER-OPERATED WINDOW, PARTITION, AND ROOF PANEL SYSTEMS." THE POWER WINDOWS MAY BE OPERABLE AFTER THE IGNITION HAS BEEN TURNED TO THE "OFF" POSITION AND THE FRONT DOORS ARE OPENED.
Consequence: THE STANDARD REQUIRES THAT POWER OPERATED WINDOWS MAY BE CLOSED ONLY WHEN THE KEY IS IN THE "ON," "START," OR "ACCESSORY" POSITIONS, OR DURING THE INTERVAL BETWEEN THE TIME THE KEY IS TURNED OFF, AND THE OPENING OF EITHER OF THE VEHICLE'S FRONT DOORS.
Remedy: DEALERS WILL RECONFIGURE THE VEHICLE FRONT END ELECTRONIC MODULE.
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.
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