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 2002 Ford Windstar owners, lightly cleaned up (personal details are redacted by NHTSA).
The rear axle of my 2002 Ford Windstar completely fractured while traveling on Interstate 75. The rear axle broke while driving about 60 miles per hour on Interstate 75 in Florida. By the grace of GOD my passenger and I survived. In attempting to stop, the van hit the guard rail on the Highway. I was able to keep the van in the right lane. The van gave us NO warning. While waiting for the AAA tow truck, a Florida Department of Transportation (FDOT} patrol vehicle stop to ensure we were alright. The FDOT driver inspected the Windstar, took pictures and stated he has never seen a broken rear axle like that before.
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.
Tl* the contact owns a 2002 Ford Windstar. While driving 45 MPH, the tire warning indicator illuminated and smoke emerged from the rear of the vehicle. The contact called lilliston Ford at [phone] (833 n delsea dr., vineland, nj 08360) and was advised that the failure could not be repaired without a diagnosis. The vehicle was not taken to the dealer for diagnostic testing or repairs. The manufacturer was not notified. The failure mileage was 72,000.
Windstar Ford 2002 tires they just keep going down very quick no holes had a blow out an wrecked into a tree with these tires bad tires ended up seat belt cut my neck an seat belt cut my 1 year olds testacles
Rear axle fractured while driving from school to home, there is uneven road surface between the school driveway or parking lot and going into the first street roads intersection, I heard a noise in the rear while crossing this uneven surface intersection, handling of the vehicle became noticeable different and a smell of burnt rubber and smoke started, after stopping the vehicle, the rear wheel was crooked and after further observation I observed the rear axle fractured close to the rear wheel (driving side) causing the rear wheel to rub against the inner wheel house and affecting control of the vehicle. …
On Saturday morning July 15th 2017, I was driving at 2:30 am. I had just left for my first job and crossed a set of train tracks. When I did, the rear axle snapped almost causing me to crash. After looking for the cost to replace the axle, I came upon a Ford recall. When I placed my VIN in the computer it came up that my 2002 Ford Windstar was in fact included in the recall. I talked to someone at Ford via live chat on Saturday after having the vehicle towed home and they stated that the recall was outstanding and I needed to call the Ford dealership. I paid again to have the vehicle towed to the dealership. Now Tuesday morning July 18th 2017, both the dealership and Ford is saying that they cant help me and I need to take care of replacing the completely rusted rear axle. The rust causing the axle to snap was the reason for the recall in the first place. …
Transmission in our 2002 Ford Windstar Mini van made abnormal noises for about 2 months. Vehicle was taken to dealership of purchase for inspection, and they attributed the problem to tire and wheel alignment. All four tires were replaced with alignment. Also, transmission noise persisted,and vehicle was returned to dealership. Again nothing wa s found wrong on inspection with instructions to return later for more complete examination. On February 10, 2005 transmission malfunctioned accelerating the engine to 3200 rpms with a speed of 70 MPH. Vehicle suddenly lost control and veered to the left into a left turn lane, resulting in a collision with an illegally parked truck and trailer. Subsequent investigations revealed the driver was unable to stop the vehicle by braking. The driver, my son , was trapped in the Windstar Mini van due to a complete collapse of the front frame. …
I heard a loud popping noise coming from the back of my van. Took it to the repair shop and learned the rear axle had a large crack and was almost broken in half. Ford has a recall in effect for 2002 Ford Windstar's for axles that are cracking/breaking (NHTSA campaign number: 12V195000); however, Ford is saying that my VIN number is not a part of their recall even though I have a 2002 Ford Windstar. I had the rear axle welded to repair the crack. This was on the passenger side of the axle. I started hearing popping sounds again, returned to the repair shop only to learn the axle is now broken on the driver side of the axle. This is a serious situation and I feel since Ford has a recall on this issue that my vehicle should be included. I am afraid to make another repair since the axle May still crack again. …
The rear axle started to snap in November 2017 when I was driving with my wife and kids in the van. We smelled burning rubber and pulled over. If we had drove any further the axle was going to snap with all of us in the vehicle. Ford is refusing to cover all the costs of the repair because the previous owner had the bracket/support put on. We did not purchase this vehicle till March 2017. We want the full cost of the repair covered and the Ford dealership's storage fees erased. Our bill is currently $1,809.65. We should not have to pay for the repair and the time it has been sitting there while we fight Ford to pay the bill. This was not an act of wear and tear but an act of a recall on the manufacturer.
Vehicle currently at the dealership for more than two months awaiting from Ford customer relationship center to resolve the issue as the dealer wont fix the corroded sub frame instead they want the crc dept send the parts to them, according to crc dept they escalated the issue to the second level but no action until now has been taken...I feel that they're ignoring my request or has been sitting there without taking any action. We almost died on this as the passenger side wheel fell off..I'm trying my luck if you can help us to resolve the issue with them...thanks [redacted]
Wheel & Tire complaints in other Windstar years
Frequently asked questions
How common are wheel & tire problems on the 2002 Ford Windstar?
NHTSA has 38 complaints about the wheels & tires of the 2002 Ford Windstar, 3% of the model year's 1,353 complaints. The component named most often is pressure monitoring and regulating systems (4 mentions).
Is there a recall for 2002 Ford Windstar wheel & tire problems?
No. NHTSA lists no wheels & tires 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 wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 108,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 2 injuries and 1 death 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.