Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
The contact owns a 2002 Ford Windstar. The contact received notifications of NHTSA Campaign Numbers: 11V030000 (STRUCTURE) and 15V608000 (SUSPENSION). The contact stated that while approaching a traffic signal and driving slowly, the vehicle shook, and the engine shifted. The contact stated that the engine shifted to the right. In addition, the contact lost control of the steering wheel. The contact stated that the RPMs became elevated. The contact pulled over into a parking lot and turned off the vehicle. The contact exited the vehicle, and upon inspection, became aware that the subframe had detached and was dragging. The contact believed that the motor mounts were fractured. The vehicle was towed to a tow yard. The vehicle was not taken to the dealer or an independent mechanic, and the vehicle was not repaired. The vehicle remained at the tow yard unrepaired. …
The contact owns a 2002 Ford Windstar. The contact stated that while driving at approximately 55 MPH, the contact pulled over and noticed that the tire was not straight inside the wheel well. While hoisting the vehicle on a lift at the residence, the contact noticed that the tire was rubbing on the inside of the wheel well and that the rear axle had fractured. The contact stated that the failure occurred at the site of the repair on the patch. The vehicle was taken to an independent mechanic and was informed about a recall. The contact called the local dealer and was informed that the VIN was not under recall. The manufacturer was contacted, but no assistance was provided. The contact stated that the failure was related to NHTSA Campaign Number: 10V385000 (Suspension). The failure mileage was approximately 160,000.
The contact owns a 2002 Ford Windstar. The contact stated while driving 40 MPH, there was an abnormal sound coming from the vehicle. The contact pulled over on the side of the road and had the vehicle towed. The vehicle was diagnosed, and the contact was informed that the rear driver's side axle had fractured. The axle was replaced. On another occasion while driving 20 MPH over railroad tracks, the contact heard an abnormal sound coming from the vehicle. The contact parked the vehicle and noticed that the rear driver's side axle had fractured. The vehicle was towed to the dealer who confirmed that the rear driver's side axle had fractured and needed to be replaced. The vehicle was repaired. The manufacturer was contacted and stated that the vehicle was not under recall. The failure mileage was 139,619.
The contact owns a 2002 Ford Windstar. The contact stated that while driving approximately 30 MPH, there was an abnormally loud sound coming from the rear of the vehicle. The contact lost control of the vehicle and drove off the side of the roadway. The vehicle was later towed to the local mechanic who discovered that the rear axle had fractured due to severe rust. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The local dealer was not notified. The failure mileage was 125,000.
The contact owns a 2002 Ford Windstar. The contact received notification of NHTSA Campaign Number: 10V385000 (Suspension) and 11V030000 (Structure) however, the parts to do the recall repairs were not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact stated that the subframe was severely corroded. The failure mileage 59,839.
The contact owns a 2002 Ford Windstar. The contact stated that while the vehicle was at an independent mechanic to replace the water pump, the mechanic determined that the rear axle was cracked and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the previous owner had the vehicle serviced under NHTSA Campaign Number: 10V385000 (Suspension). The failure mileage was approximately 116,000.
Axle broke on rt side just underneath the bracket that ford installed for recall.i was only going 10mph when it happened no warning I was able to gain control and stop was towed into a shop not driveable if this seems to be a problem mine looked fine they must filled it up with expand foam I would think that would trap in more moisture but these are dangerous they should all be fixed or bought back from the customer
Rear Axle . Fell on the highway split in half while I was driving on a state Hwy 71 at 45 mph. Cracked rear axle. 2002 Ford Windstar part of a recall for Rear axle. No warning was given and didn't know about the recall until after it happened. Inspection was preformed by a mechanic. I could have flipped or rolled or caused a major collision as this highway is very heavily traveled.
Broken rear axle on the van. The axle has broken where the reinforcements were welded in from the recall in 2010. NHTSA action number is PE10016. So, the corrective action did not work and now I have broken axle as a result. The axle broke while driving the van and we were very fortunate to be driving at a slow rate of speed.
Tl* the contact owns a 2002 Ford Windstar. The contact stated while driving 20 MPH she stated smelling burnt rubber and then notice smoke coming from the rear driver's side tire. The contact pulled over and called her mechanic who stated to her "not to drive the vehicle." the vehicle was towed to the independent mechanic who diagnosed the failure as a fractured rear axle. The contact stated that the independent mechanic advised her of an unknow recall in which the a kit was placed on the rear axle. The contact stated that the prior owner had the vehicle serviced under an unknown recall for the rear axle. The contact stated that the vehicle was then towed to wilson Ford in new jersey to be serviced under NHTSA campaign numbers: 11V030000 (structure) and 15V608000 (suspension). …
Related recalls
Suspension › Rear › Axle › Non-powered axle assembly
Ford Motor Company (Ford) is recalling certain model year 1998-2003 Windstar vehicles manufactured September 2, 1997, to July 3, 2003. The affected vehicles were previously remedied to safeguard against the rear axle cracking from corrosion, however, the remedy brackets may have been misinstalled.
Remedy: Ford will notify owners, and dealers will inspect the brackets to verify their proper installation. If a bracket is found to have been misinstalled, the rear axle will be replaced.
Suspension › Front › Control arm
Ford is recalling certain model year 1999-2003 windstar vehicles originally sold in or currently registered in the state of virginia. Corrosion-related fractures of the front lower control arm rear attaching brackets and body mount attachments May occur.
Remedy: Dealers will inspect both front lower control arm rear attaching brackets and both body mount attachments at the rear of the front subframe and make the necessary repairs free of charge.
Suspension › Rear › Axle › Non-powered axle assembly
Ford is recalling certain model year 1998-2003 windstar vehicles manufactured from September 1, 1997, through July 3, 2003, registered in puerto rico. Due to increased stresses caused by high cycles of torsional loading, specific to this market, the rear axle can crack.
Remedy: Ford will notify owners, and dealers will inspect and install a reinforcement bracket on the rear axle or replace the axles, as necessary. This service will be provided free of charge. The recall began on June 1, 2012.
Suspension › Rear › Axle › Non-powered axle assembly
Ford is recalling certain model year 1998-2003 windstar vehicles manufactured from September 1, 1997 through February 28, 2003 and currently registered or originally sold in connecticut, delaware, district of columbia, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new…
Remedy: As parts become available, dealers will inspect and if necessary install the rear axle reinforcement brackets free of charge. This service will be performed free of charge. The safety recall began on October 20, 2010.
NHTSA investigations
Rear Axle Cracking
In a letter dated August 26, 2010, Ford Motor Company (Ford) submitted a Defect Information Report notifying NHTSA that it will conduct a safety recall (NHTSA Recall No. 10V-385) to address a rear axle defect in model year (MY) 1998 through 2003 Ford Windstar vehicles built at the Oakville assembly plant from September 1, 1997 through February 28, 2003 and either sold or currently registered in high corrosion…
Suspension complaints in other Windstar years
Frequently asked questions
How common are suspension problems on the 2002 Ford Windstar?
NHTSA has 279 complaints about the suspension of the 2002 Ford Windstar, 21% of the model year's 1,353 complaints. The component named most often is rear (87 mentions).
Is there a recall for 2002 Ford Windstar suspension problems?
Yes — NHTSA recall 15V-608 (non-powered axle assembly, Sep 29, 2015); NHTSA recall 12V-194 (control arm, May 3, 2012); NHTSA recall 12V-195 (non-powered axle assembly, May 3, 2012). Recall repairs are free at authorized dealers.
At what mileage do 2002 Ford Windstar suspension problems start?
Half of the complaints with a recorded mileage happened before about 133,000 miles, and 1% before 25,000 miles.
Is it dangerous?
Owners linked 7 crashes, 7 fires and 4 injuries to suspension 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.