Which parts fail
Components named in complaints (wheels, lug nuts, original-equipment tires, TPMS).
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).
We were driving at approx. 45 MPH when the front passenger wheel came off and rolled into on coming traffic. My the front passenger side was smashed as the vehicle skidded to a stop. Fortunately no one was injured. The repair technician said that it appeared the bolts had somehow sheared off. We had not had any recent repairs to the wheels and had not changed tires since November 1999. My husband and 2 young children were in the car when the accident occurred. The police drove by and when they saw that no one was injured did not stop to take a report. The accident was reported to our insurance company and we were required to pay our $500.00 deductible. We contacted Ford motor, however, they denied any similar complaints. This accident occured in March.
Had changed brake pads a week earlier. Driving 55mph and the car crashed down on it's axle as the tire and wheel passed by us going down highway, in 37 north. Studs had all broken off. The disc brake is ruined from skidding on it. Traffic was moderately heavy. We skidded to a stop on a bridge and feel lucky not to have crashed into anyone.
When traveling at 35 MPH when the left rear tire blew out, pushing the vehicle into another lane, causing an accident, and resulting in injuries to the driver. Consumer has contacted the dealer. Please provide any further details.
Consumer stated the lug nuts on the front passenger side wheel were sheared off. Consumer stated while driving on the highway at about 50 MPH, the vehicle started to shimmy violently almost out of control.
In 1999 when turning to the right, we experienced a grinding noise. My husband removed the hubcap and found the steel rim of the wheel to be cracked badly. We contacted the manufacturer and the dealer who both said it was a serious problem, but that the other should pay to have it fixed. Because I put my 3 small children in the car, I paid to have it fixed. Two years later, we have found two more wheels have cracked. This time, we contacted the dealer and the manufacturer agreed to help pay for the repair. The speedometer was the first "problem" we came across with this car. At speeds of over 40mph the needle would go sporactically back and forth between about 35 and 110mph. We were told it would be $400 to replace so, we have not yet had it fixed. Since the first few months of its occurance, it only moves back and forth 5mph up or down of our speed. …
The original wheels on my 1996 Windstar have developed air leaks at the welds. The first time this happened, I went to a salvage yard for a replacement, and they said Windstar wheels are scarce because this seems to be a common problem. I have replaced all four wheels within the past two years. I believe the OEM wheels are defective. (in 34 years of driving, I've never had this problem with even one wheel on any car. 4 out of 4 wheels with the same problem on this van tells me something is wrong with the product.) our driving is on good roads, so it cannot be attributed to rough use. The only consequence so far is that tire pressure is slowly lost, leading to low pressure. Our only expense so far is that we have had to replace all the wheels, one at a time. …
On August 16, 2000 I was the victim of a minor automobile accident that occurred when a new fr440 tuwsps21570r15 tire, purchased on May 22, 2000 and located on the front right side of the vehicle, explicably burst while I was traveling around a corner at a low rate of speed. My minivan slid off the side of the road and into a tree, doing damage to the body and the frame. The tire was so shredded after sliding off the road it was impossible to tell what caused it to burst. However, I had purchased road hazard insurance on the tires (after replacing tires I had just bought in April that were punctured by a sharp stone). A Firestone tire center would not fix the damage caused in the accident and I was forced to utilize insurance to repair the damage. The tire had approximately 5,000 miles in usage when it burst. (tiresize: 21570r15)( dot number: tire size: 21570r15 )
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.
The front right wheel sheared off the lugs and caused the wheel to just about fall off while we were driving the car. The dealer replced the lugs (only the broken ones and not all of them). Just over one year later, the exact same thing happened; that is, the right front wheel sheered off the lugs and caused the wheel to almost fall off. A few months prior to the second incident, all 4 tires were changed by an independent tire place. That tire place swears up and down that they properly torqued the bolts and that their standard inspection calls for a second inspection to confirm this. I tend to believe that they did this. I think there is a known defect in the wheel design by which the lug nuts are known to back off during use, causing the wobbly wheel to shear off the other lugs. I have seen this condition reported by others on this site.
My aluminum wheels have corroded at the tire bead seat severely. This produces tire pressure loss constantly. The wheels are not corroded at the face but at the area where the tire seals. My local tire store in michigan says they see this same issue regularly. I am a Ford engineer and have complained about this defect to the wheel engineers and they say there is no such problem. The tire store also added that aluminum wheels combined with Michelin tires are the worst. Two of my wheels have this problem now with the original tires. This is a safety problem as they keep loosing air. I have to add air once a week.pls call me- I can show them to you. I dismounted the rears and the corrosion is severe. I take care of my cars-there is no excuse for this level of corrosion. Thanks. (tiresize: 215x70x15)
Wheel & Tire complaints in other Windstar years
Frequently asked questions
How common are wheel & tire problems on the 1996 Ford Windstar?
NHTSA has 60 complaints about the wheels & tires of the 1996 Ford Windstar, 4% of the model year's 1,386 complaints. The component named most often is lugs/nuts/bolts/studs (16 mentions).
Is there a recall for 1996 Ford Windstar wheel & tire problems?
No. NHTSA lists no wheels & tires 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 wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 133,000 miles.
Is it dangerous?
Owners linked 4 crashes, 0 fires and 3 injuries to wheels & tires 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.