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 2002 Ford Windstar owners, lightly cleaned up (personal details are redacted by NHTSA).
Exiting highway from off ramp into 4 lane red light intersection at normal speed. Applied brakes, no reaction to slow down. Pumped brakes still no slowing. Drove car into shoulder and field at off ramp. Car went through chain link fence and finaly came to a stop when it hit a tree. Police responded. No injuries or major property damage. Car was towed to garage and finally Ford dealer. The brake module failed. Month old inpection, no brake problem. Police commended fast thinking to avoid a major accident invovling hitting any other vehichles. I have a police report but I do not have a scanner.
I''m reporting this as a fire hazard. The vehicle was in the driveway and began to smoke. The vehicle is in good repair, not neglected or abused. I located the source it was the ABS module and disconnected the battery until I could make arrangements with the dealer. I drove the vehicle to the dealership. The ABS module had failed and burned the wiring harness. There were no warning lamps or fuses burned. I questioned why there was no warning and shouldn''t there been safeguards in place to prevent such damage. I asked if there were other cases of the same occurrence and the dealer didn''t know. I asked if there was someone else I could contact and they told me I could call Ford customer care. …
My van brake light and ABS light had been coming on for at least 6 months... My mechanic was trying to determine if it was the ABS switch or ABS module and just reset the codes after a tune-up. We would add brake fluid to the car on several occasions. The failure occurred when I started my van and backed out of a parking spot. I smelled something burning and realized my van was smoking. At first I thought it was steam and then I realized it was white smoke. So I reparked my vehicle, shut it off and popped the hood. When I got around I followed the engine from left to right and in the back right was a perfect propane flame. I blew it out. I noticed the part was connected down below the brake fluid reservoir, wired ran to that part, on the bottom the part that was on fire was rusted. But it appeared to plug into the part it was attached to like a key and then wires came down from there... …
The morning of July 11, 2010, the ABS control module on our 2002 Windstar suffered an internal fire due to brake fluid leaked from the bad switch, resulting in a loss of proper brake function and no readings from the speedometer, tachometer, and odometer (as well as multiple warning lights). This occurred several weeks after having had the brake pressure deactivation switch recall performed (NHTSA campaign id 09V399000, action number ea08021). The local Ford dealership which had performed the initial recall work refused to repair or replace the module under the recall or as a warranty claim, stating that it was not part of the recall, nor was it apparently damaged at the time of the brake switch repair. I subsequently removed, opened and examined the control module (8/28/2010), and found blackened brake fluid present inside the module at the connector pins. …
2002 Ford Windstar sel with VIN [redacted], I am the third owner of this vehicle. The ABS and traction control system is damaged and has a recurring warning when the engine is started with the ABS / brake and traction control warning lights on. The person I purchased this van from (2nd owner) stated that he had all the recalls completed on this vehicle however he believed that the defect identified in Ford safety recall 09s09 for the speed control system has resulted in damage to the ABS system computer and/or associated harness wiring or harness connections. He (2nd owner) did not keep the repair orders for any of the recall repairs so I do not have any records to review. I believe that the wire harness, related wire harness connectors and the ABS system computer are damaged resulting from brake fluid leaking and/or corrosion related to the defect found in Ford safety recall 09s09. …
Tl contact owns a 2002 Ford Windstar. While driving approximately between 35-40 MPH on normal road conditions; pressure was applied to the brake pedal the front btakes locked and the driver was unable to turn the steering wheel. The vehicle also skidded without warning. The failure continued to occur intemittently. The "brake" and "ABS" warning light indicators illuminated on the instrument panel. The warning indicator remained illuminated until the engine was shut off by the driver. The contact was able to drive the vehicle with caution; however, there was an increase in the engine rpms. An authorized dealer replaced the intake manifold gasket and the alternator. On a separate occasion, the the air bag system failed to deploy with a level of impact to the rear of the vehicle. There were no personal injuries. The contact had concerns of the safety risk involved. …
While partially parked into the garage, after driving for one hour and sitting for half of an hour, smoke was observed from under van. Smoke stopped and noticed "ABS" warning light on. Brakes worked, but cruise control did not. Dealer installed/ replaced: 1) brake kit/ brake pressure deactivation switch, 2) ECM control module, 3) valve asy. 4) two wiring harnesses (one was a used from a Ford escape, due to the availability and cost.), 5) two fuses, 6) brake fluid and misc. Shop supplies. It was at the dealer for 11 days, cost for repairs was $1831. Drove it 5 miles and "check engine" light came on. The dealer stated this was not related to original problem. It was the dpfe sensor: $331 to repair. Normally the van is garaged, luckily something was in the way of fully pulling it into the garage and the fire went away quickly. …
Neighbor came by early and told me the brake lights were on. I went out to inspect but didn't see them on. Got in the car an hour later and noticed smoke and horrible "electrical" smell. I checked the entire car, but found nothing, when I went to start it, the battery was dead. Had my friend give me a jump, hooked up cables and sat in the Windstar for a minute, I then heard crackling and immediately smelled smoke. Under closer examination I found it was the center, upper brake light assembly completely melted, bulbs were contorted. Had the assembly replaced with a Ford part from dealer, three days later it happened again, so I removed bulbs before it completely melted. The center "third" brake light does not shut off, even when car is off, 12, strong volts to bulb socket, on or off! Left and right brake lights work fine...for now. …
Red brake light and yellow ABS light came on while driving. It suddenly decreased in its braking power and resulted in a minor bumper to bumper crash at a traffic light. Luckily no major damage was done and no one was injured, only small stretch marks on my front bumper. The other persons car was OK and we went on straight back home shaken and afraid the whole ride back. This vehicle has already had the company friendly (not consumer friendly) recall NHTSA campaign id number: 09V399000. This seems to have made the problem worse though. The dealer says it is a common problem with the windstars and there is no recall for the ABS system and could cause braking distance to decrease and advised me to have it repaired immediately as it is a safety hazard!!!! The government and odi got right up on toyotas for not being able to stop and not fords!! This must be recalled and fixed immediately!
While driving at 20 MPH,the driver stepped on the brake pedal and the brake pedal had a delayed reaction, which resulted in the vehicle hitting a wall head on. Dealer had been notified. When the first incident occurred, the brakes were engaged but did not stop the vehicle, the engine revved and the vehicle kept going. The vehicle had run into the corner of the flower wall of the stores sign. The second incident was similar, but the consumer was in a school zone at a stop sign and the engine revved, the consumer applied the brakes, the vehicle jumped but did not stop. Pressure was applied three times to the brakes, then the vehicle finally had come to a complete stop. The problem was unable to be duplicated.
Brake complaints in other Windstar years
Frequently asked questions
How common are brake problems on the 2002 Ford Windstar?
NHTSA has 643 complaints about the brakes of the 2002 Ford Windstar, 48% of the model year's 1,353 complaints. The component named most often is antilock/traction control/electronic limited slip (29 mentions).
Is there a recall for 2002 Ford Windstar brake problems?
No. NHTSA lists no brakes recall for the 2002 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 2002 Ford Windstar brake problems start?
Half of the complaints with a recorded mileage happened before about 95,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 8 crashes, 20 fires and 3 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.