Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
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).
Consumer complained about a brake problem. The brake line ruptured, causing the vehicle to crash into a tree. A recall was issued on this make, model and year. But the vehicle identification number was not included in the recall.
My 1996 Ford Windstar was parked "in park" in my driveway, without the keys in the ignition, and just rolled downed the driveway and crashed into a stone wall. There is significant undercarriage damage to the car and wall damage.
The 1996 Ford Windstar continues to have defective head gaskets as in 1994 and 1995 models. This lead to engine failure at 78,000 miles! The cost to replace the engine per miller Ford was 4,778.00. We paid 19,000 for this vehicle and refuse to pay for a new engine! The nasa has stated the head gasket should last at least 120,000 miles or the life of the vehicle. We have had this Ford Windstar with a blown engine due to head gasket failure since last December, but continue to make monthly payments on this dead Ford Windstar. We pay taxes, insurance, and montly payments to Ford credit for the next 18 months or so. We just discontinued registration fees as the dmv told us we could do this. Ford refuses to acknowledge this problem and is not standing up to it's committment of quality care to it's customers. I urge anyone who is considering buying a Ford to do their research. …
I maintained my Windstar properly. It began to leak coolant and engine light. Ford dealership stated it needed a new engine. Due to faulty head gasket causing leak of coolant. Ford Canada agreed to cover some of the cost but not all of it. Said if I declined their offer they would withdraw all offers. So I took it. I couldn't afford the bill as it was. I have since seen a small claims court in quebec found that Ford was responsible for the repairs related to the head gasket. I have contacted Ford Canada customer complaint center. And told they will not reimburse me for the expenses. And that although they lost the complaint in quebec in all other canadian proviences they have one. Even a class action suit. Why would they pay a portion of the repair if they were not responsible??? I feel they are responsible for the full cost of the engine repair.
Brake pedal went to floor and no brakes in normal stop on dry pavement. Then brakes were fine. 2 wks later happened again so took to Ford. Ford replaced all brakes due to heat from slightly set emergency brake (warning light was burned out they said). Brakes to floor, but manuel brakes the next day. Ford drained brake lines. Happended again. Ford said you will have manuel brakes--it takes a while for new brakes to settle in. Kept happening-pedal to floor, manuel brakes, then normal braking. No improvement in 2 months so returned to Ford. Ford said no problem. On 12-22 rear ended a truck as brakes failed with no manuel brakes available. Ford says no problem. Ford engineer refuses to talk with me and sends the message that there is nothing that can cause that kind of problem. I don't know what to do.
This morning, I was preparing to back out of my driveway when, all of a sudden, the brake pedal went to the floor. I had completely lost my brakes and brake fluid was spilling onto the driveway. Upon investigating the leak, my neighbor and I were able to locate a crack in the right front hard line. There was obvious signs of corrosion on all of the hard brake lines. I have not received any notification of defective brake lines and was unaware of any problems until I reviewed the information on this site. I am not sure whether to contact Ford directly or speak with an attorney first. I shudder to think of what May have been the result if this had occurred on the interstate while on a family trip rather than in my driveway.
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.
I have a 1996 Ford Windstar that has developed a leak in its brake line. I went on the internet to find a brake line for the car and I found out that this is a chronic problem with this vehicle. There was a recall for this exact problem from Ford. I contacted Ford and told them of the problem and they stated to me that my vehicle was seen by a Ford dealer for the recall in 2002. They then told me to contact my local dealer and find out if this would be covered by Ford. I contacted my local dealer and they told me that if the car was already recalled for this problem that it would have to be paid for by me. I looked at the brake line and it does not look like it was ever replaced. The recall # is 02V101000 .
The brake & ABS lights were coming on intermittently then the brakes started squeaking and eventually started at least scrubbing on the right side. Also, when you push the brake pedal down, it felt soft. This started happening again at the beginning of October of this year and the right front brakes are scrubbing. And, the brake pedal feels soft, again. My husband replaced the brakes on 12/28/09 and we had to have the right front axle and spindle replaced on 01/13/10. We had the recall no. 09s09 work performed at richard haney Ford in carrollton, georgia on 12/17/09. New front brakes were also put on by mechanics on 12/12/08 & 09/17/07.
The consumer requested an investigation of Ford motor company and their lack of recalls on some serious defects. The vehicle experienced a clunking sound, however the dealer stated the clunking sound was normal and then the transmission failed, the transmission was replaced with another Ford transmission, which failed on a test drive and one other occasion. Coolant leaked into the engine through the intake gasket, which was recalled for the 95 models. The timing chain leaked. There was a recall on the coils in the suspension, which Ford would only replace when they failed. The brake rotors failed at 30000 miles. Scc
Related recalls
Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittings
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, wisconsin, and the district of columbia.
Remedy: Dealers will inspect the brake line for corrosion and clearance conditions. A brake line that is not corroded will be repositioned.
Service brakes, hydraulic › Foundation components › Master cylinder
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.
Remedy: Owners will be provided with new labels and installation instructions.
NHTSA investigations
Hydraulic brake line failure
On April 4, 2002, Ford motor company notified odi of a defect condition that could result in extended stopping distances in approximately 250 thousand model year (my) 1995 and 1996 windstar minivans sold or registered in salt belt states (recall 02v-101).according to Ford, improper brake line routing in vehicles manufactured at the oakville assembly plant from January 14, 1994 through May 21, 1996 resulted in some…
Rear axle trailing arm
There is no summary currently available
Brake pedal fade/extended stopping
Odi has received sixty-eight (68) consumer reports of alleged failures or malfunctions in the brake system on certain 1995 and 1996 Ford windstars, which resulted in brake pedal fade and in extended stopping distances during brakingthese alleged failures or malfunctions are reported to have caused twelve (12) accidents that resulted from vehicle loss of braking.the conplainants report that the loss of braking…
Brake pedal fade/extended stop distance
There is no summary currently available
Brake complaints in other Windstar years
Frequently asked questions
How common are brake problems on the 1996 Ford Windstar?
NHTSA has 229 complaints about the brakes of the 1996 Ford Windstar, 17% of the model year's 1,386 complaints. The component named most often is antilock/traction control/electronic limited slip (115 mentions).
Is there a recall for 1996 Ford Windstar brake problems?
Yes — NHTSA recall 02V-101 (hoses, lines/piping, and fittings, Apr 4, 2002); NHTSA recall 99V-147 (master cylinder, Jun 14, 1999). Recall repairs are free at authorized dealers.
At what mileage do 1996 Ford Windstar brake problems start?
Half of the complaints with a recorded mileage happened before about 89,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 18 crashes, 6 fires and 6 injuries to brakes 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.