Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
Tl* the contact owns a 1996 Ford Windstar. The contact stated that there was a very strong fuel odor inside and outside the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 240,000.
1996 Ford Windstar FWD auto pb ps pw ac, v-6. Vehicle auto accelerated when put into reverse. Brake loss due to lack of vacuum. Vehicle spun in a circle suddenly and hit another parked vehicle when backing out of a parked position.
Engine dies after either very short (1 second or less) or no misfire. Always on hot afternoon after long period highway driving, typically interstate with speed in the 70's. Only once on a secondary road speeds of 45 - 50. All times in the rolling hills of utah, wyoming, and western north dakota. All six incidents occurred during a cross country trip in July, 2005 with odometer readings in the 70,000's. Typically, when it happens, the engine speed and throttle are continually adjusting to maintain speed across the hills. First indication often is simply the car slowing down rather that cruising along. All other electrical (air, radio, windows, etc) not affected. This is very dangerous. Other than sometimes a one second misfire, there is no warning. The car May be passing a truck, in a middle freeway lane, on on a road with no shoulder when it happens. …
I have a concern over the defect of the head gasket of our 1996 Ford Windstar. This vehicle is our family vehicle - very neccessary for a family of young children - family of 7. So far, we have replaced the transmission, replaced the speedometer, and most recently have been told to replace the head gasket. I understand that the head gasket repair/ replacement is a rather expensive repair. I also understand that Ford has offered to some, to make good on this defect in workmanship. I have been advised to turn this in to the state's attorney here in north dakota, and to the better business bureau. I need this vehicle fixed. I don't care for the Ford dealership in jamestown, nd - since the last repair left me without a vehicle for a month. I would like this defect taken care of. …
The vehicle had a fuel leak at the fuel tank. I removed the tank to see that the tank looked like it was pinched and developed a crack. The fuel tank is plastic so I found this to be odd. I had to put epoxy on the tank to patch the crack so I could get it home as I was out of town when this happened. When I got home I started looking online for a tank and found that Ford had a recall on this matter. I called lafayette Ford and explained the recall and gave my VIN #. I was told that my vehicle does not fall under the recall that I will have to repair it myself. If I have the same vehicle of the recall and the same problem of the recall why does Ford not honor it. The recall states the crack at the front strap area and that Ford will replace the tank and the strap with a longer one and a bushing. …
Dt*: the contact stated there was an odor of fuel in his garage. The vehicle was taken to the dealership, but a determination was not given. There is a NHTSA recall, # 99V309000, regarding the tank assembly; however, it is not included in the recall due to the VIN. Updated 5/30/2006 - the consumer inspected the vehicle and found that the fuel tank was leaking at the strap on the driver's side. The tank began to leak where the manufacturer has apparently over-tightened the support straps for the tank. The 1995 model was recalled (99v-309000), manufacturer number 99r33 regarding the exact same issue. The consumer contacted the dealer but they provided no assistance. Updated 06/27/06.
On June 7 I was outside of our home and noticed I smelled gas near my wife's van. After inspecting I saw the tank was leaking fuel. I took the tank off and noticed there was pressure to the tank from the front strap. The pressure caused what appears to be a stress crack where the strap holds the tank. It appears to me the strap is too small for the tank. Ford refuses to fix this and would rather my wife and children ride around in a gas leaking danger machine. This vehicle has less than 95000 miles and I feel the same problem has occurred here as in the 1995 Windstar.
While driving approximately 65 MPH windshield started to fog up. Driver rolled down window for driver's door when a "popping" noise could be heard, and flames could be seen coming from vehicle. When vehicle was stopped, heavy smoke started coming from under the hood, and vehicle was engulfed in flames. A fire lieutenant suspected that fire was due to leaking fuel in engine compartment. Vehicle has not been inspected by the manufacturer or insurance company. Please provide any additional information / documentation.
Gas tank leak. I leave in one of the states that is listed in recall 99V309000 that states hot weather increases cracks in fuel tanks on 1995 Ford windstars. My vehicle is a 1996 with a build date of 10-02-1995. Ford motor will not consider this vehicle for replacement. They need to re-evaluate the recall to include a wider range than they now have. I was told by the dealership that my leak looks just like a 1995 they fixed on 07-23-2004. Please help on this safety issue.
The 1996 Ford Windstar has a fuel tank on it that is identical to the 1995 Ford Windstar. The 1995 was recalled for a leak on the upper portion of the tank. The 1996 version was not recalled. My 1996 leaks same place as the 1995 recalled version. Dangerous fuel can seep down tank and drip on exhaust system or other components to cause fire or explosion. Ford does not want to replace tank on 1996. Nothing was done by Ford to correct this problem.
NHTSA investigations
Fuel tank fatigue cracking
See attached report.
Fuel tank cracks
There is no summary currently available
Fuel System complaints in other Windstar years
Frequently asked questions
How common are fuel system problems on the 1996 Ford Windstar?
NHTSA has 52 complaints about the fuel & propulsion system of the 1996 Ford Windstar, 4% of the model year's 1,386 complaints. The component named most often is storage › tank assembly (18 mentions).
Is there a recall for 1996 Ford Windstar fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 1996 Ford Windstar, though it has 8 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Ford Windstar fuel system problems start?
Half of the complaints with a recorded mileage happened before about 120,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 1 injury to fuel & propulsion system 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.