Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Ford Windstar owners, lightly cleaned up (personal details are redacted by NHTSA).
Complete brake loss when the brake was applied. The brake pedal went all the way to the floor without warning. Luck had it we were pulling into a parking spot with a concrete stop. The metal brake line located above the gas tank rusted completely. While the rest of the brake lines look fine, it's the area of the brake line that passes over the gas tank that is rusted. Because of the location of the gas tank, the line are hidden from normal view of an inspection unless the gas tank is lowered. Had this occurred at a busy intersection or highway at high speeds this could have been catastrophic. The brake lines were replaced. The old part is available. I am keeping this as a reminder how close my family came to death.
Driving approxiamtely 55mph when the top part of the hood just flew off the van. This is a two part hood and the bottom part was still locked. Vehicle was also involved in a minor accident while going 20-25 MPH. Took in for repair, but did not get repaired because they said it was not under warranty.
While driving 65 MPH with cruise control on vehicle sped up. While getting ready to exit off the highway vehicle stayed under cruise control module. As consumer attempted to slow down, vehicle was moving 65 MPH without any control from consumer. In order to make vehicle stop consumer had to press brake pedal with both feet, and shift vehicle into neutral. Eventually, vehicle was able to slow down, and consumer turned vehicle off, dealer replaced 2 lock tabs because one had slipped on the cruise causing it to stay on. Trip speedometer was replaced, it would not go past 799 miles. At 30 MPH and over, the over drive light will flash. Left front wheel cover was replaced due to it making ticking noises at lower speeds. Sliding door squeaked, dealer lubed the sliding door. Front rotors replaced and rear drums turned, a clicking noise was heard.
Nothing but problems since purchasing 1)door ajar light constantly illuminated-all doors checked none ajar 2) engine check light occasionally comes on-happened right after purchase and catalytic converter replaced obviously didn't fix problem 3)occasionally power windows/locks and A/C will go out unless adjustable fan speed turned to high 4)recently front passenger door will open at random usually during a turn-luckily no one sits in that seat 5)speedometer will occasionally flicker higher while driving at speeds greater than 65mph all of these problems have surfaced in the past 1-1.5 yrs and have continued since then.
1996 Ford Windstar, speedometer malfunction. Speed is impossible to determine as the needle fluctuates wildly. Problem has persisted now for at least 50,000 miles , but I just learned that you should be notified so that Ford can be held accountable for poor quality and non support. As I was advised that repair would be about 600.00. As I have a tach, I simply use this to determine my speed. I was not about to spend that amount of money on what I consider a design flaw.
Head gasket leaking, master cylinder froze up and caused smoke and damage to brake system on 3 wheels, ABS light kept coming on, in for repairs on several occasions and light was disconnected by dealer, engine light on: o2 sensor replaced, speedometer failed to register speeds, driverside window goes down while driving, replaced by dealer, door open light turns on randomly, sliding door fails to lock with electric locks. What is going to be next?
The sub-frame broke where the strut arm connects in the front( in area of the strut arm bushings. At first thought that the noise was from at loose heat shield. Strut arm rattles everytime van iecounters rough pavement. The speedometer just went haywire. Needle bounces all over the place. Have found other people on the internet with the same speedometer problem. I feel that both of these failures are a saftey issue. Ford motor doesn't.
Front brake rotors: due to rotors warping, they have been replaced 3 times since I purchased the vehicle. All have been covered under original warranty. Now, my warranty has expired, and therefore, I am stuck with any future problems. Passenger side sliding door: rust was found on inside bottom of door. It was temporarily fixed; dealer is waiting for Ford to approve new door to be installed (under original warranty).
While traveling on the interstate, check engine light appears on dashboard, and vehicle was leaking antfreeze. Dealership is aware of problem. Dealer found head gasket had blown, replaced head gasket and thermostat, on several occasions the air conditioning leaks, brakes making grinding sound, dealer found anti-lock sensor failed, rear fender is rusted on passenger side.
Ford extended warranty on 3.8 l engine for 1995 model due to engine failure caused by defective gasket sets. However, is not doing so for like failure on 1996 model 3.8 l engines. Engine seized on our vehicle with approximately 48000 miles despite maintenance and timing chain gasket set replacement an approximately $1200 repair. Dt
Related recalls
Structure › Body › Hood
Vehicle description: passenger vehicles and Mini vans. Tearing of the bond between the inner and outer hood panels during minor front end collisions can result in a gap at the leading edge of the hood. Air forced between the inner and outer panels can produce enough pressure to force the outer panel upward.
Remedy: Dealers will inspect the hood area for any damage along the leading edge of the hood. If there is any evidence of bond separation, the hood will be replaced.
NHTSA investigations
Outer hood panel detachment
The office of defects investigation has received 6 reports indicating the outer hood panel separated from the vehicles as they were being driven.Ford has provide 39 additional reports that are consistent with odi reports.Ford indicates that the likely cause is prior collision damage.this investigation is being upgraded to further study this issue.
Outer hood panel detachment
There is no summary currently available
Body complaints in other Windstar years
Frequently asked questions
How common are body problems on the 1996 Ford Windstar?
NHTSA has 37 complaints about the body & structure of the 1996 Ford Windstar, 3% of the model year's 1,386 complaints. The component named most often is body › door (14 mentions).
Is there a recall for 1996 Ford Windstar body problems?
Yes — NHTSA recall 97V-180 (hood, Oct 20, 1997). Recall repairs are free at authorized dealers.
At what mileage do 1996 Ford Windstar body problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.