Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
There was a safety recall initiated by Ford for corrosion of the engine cradle - 2003 Ford Windstar structure: frame and members:underbody shields NHTSA campaign #11V030000. Ford repaired the left side only, leaving the right side rusted and now several significant rust holes have appeared on the right side. Ford disclaims any responsibility saying that they made the repair properly but I claim they made the repair inadequately. Bad metal is bad metal and regardless of the fact that the holes were discovered over a year later is inapplicable as good metal does not rust through to the point of creating a safety hazard. If the engine cradle fails, the engine will fall from the vehicle, potentially while moving. Gas will spew across the road and a fireball will ignite. …
Purchased new in 2003. This vehicle has electrical problems and yet we are being told that we have to eat the financial bills instead of Ford. From sensors failing, to interior lights flashing at us, and the vehicle sputtering while we drive down the road. Ford knows that the 1999- 2003 Windstar have serious safety and electrical failures, yet they do not want to correct the problem at their cost. Ford would rather pass on their problems onto the consumer and at the consumer's cost. 2013 at our cost of $1,000.00+ we replaced the coil assembly pack, EGR system with brackets, oxygen sensors, spark plugs, and wires. Now we are replacing them again. The ABS system, the traction control, and the cruise control all interwoven and all failed in 2009 and we were told that it is not important by the dealerships. We placed our OBD scanner on our vehicle and this is what we pulled. …
Tl* the contact owns a 2002 Ford Windstar. While examining the vehicle, the contact noticed rust along the filler pipe on the driver side of the vehicle. The vehicle was taken to the dealer but the contact was not informed what was causing the failure and the vehicle was not serviced. In addition, while traveling 30 MPH, the contact noticed that the front end of the vehicle would begin to sway left to right. Moments later, the rear of the vehicle had also begun to sway from left to right. The contact examined the vehicle and discovered that the front torsion bars were hanging off of the vehicle and the rear axle was partially separate. The vehicle was not diagnosed by the dealer nor repaired. The current mileage was 100,000 and the failure mileage was 65,000.
Tl* the contact owns a 2002 Ford Windstar. The contact stated that the vehicle was taken to the dealer for repairs under NHTSA campaign id numbers: 11V030000 (structure: frame and members:underbody shield) and NHTSA campaign id number: 10V385000 (suspension:rear:axle:non-powered axle assembly). The contact stated that the it took over eight months to perform the repairs and the vehicle became inoperable after repairs. The dealer stated that the battery and fuel pump had become defective and would need to be replaced. The manufacturer was contacted who did not offer any assistance. The vehicle was not further repaired. The failure and current mileage was 193,000.
Brakes continually have failed causing accidents. Pedal goes all the way to the floor before and after new brake pads and bring bled.throttle idle sensor causes vehicle to stall while driving. ABS light and brake light and check engine light keeps coming on. Now they just stay on. I need to know what,if any recalls have been repaired or any options that May be available.
Tl contact owns a 2001 Ford Windstar. When the contact first purchased the vehicle, it shut off. The rings in the engine had to be replaced. She also heard a rumbling sound when the brake pedal was depressed. An auto repair shop stated that the brakes were operating normally; however, after much complaining, the contact had the front brakes replaced. The windshield wipers stopped working after a new windshield was installed. The vehicle was diagnosed and the motor was found to be the cause of the failure. The motor was replaced. A couple of months later, the vehicle began leaking antifreeze and was towed to a repair shop. The contact was informed that the fuel injection hoses were leaking. The leak was repaired. Three weeks later, the vehicle would buck and shut off. She was informed that the catalytic converter was completely destroyed. …
I had been having problems starting my 200 Ford Windstar se. On Monday, jan. 8, 2007, I drove my van to get coffee, came home and parked it in the driveway. A few minutes later, I noticed smoke and flames. The car burned out, despite the efforts of our local fire dept.
My 2000 Ford Windstar will stall, while driving, without warning causing a loss of power to the engine, braking system and steering system in a 3800 pound vehicle. This is an intermittent problem, but repeats itself every 2 or 3 weeks or so. The last time it caused my wife to transverse into a stop sign controlled intersection in a populated residential area of los angeles county without brakes or steering. It has happened 15 times to myself and my wife and twice to south bay Ford since approximately nov of 2004. I believe that Ford dispatched engineers to south bay Ford in hawthorne california who stated that this is an issue of fuel tank design and is not correctable. South bay Ford and Ford motor company together appear to be ready to return the vehicle to me with the instructions "don't let the fuel tank drop below 1/4 of a tank". …
Related recalls (2)
Fuel system, gasoline › Delivery
Vehicle description: Mini vans. These vehicles May have incorrectly fuel line end forms which could result in a lower than specified pull apart force for the installed fuel line connection.
Remedy: Dealers will install a redundant fuel line clip on the fuel supply and return line connections at the rear of the chassis fuel line bundle.
Fuel system, gasoline › Storage › Tank assembly
Vehicle description: minivans which were originally sold or currently registered in the following hot weather states: alabama, arizona, arkansas, california (10 southern counties), florida, georgia, hawaii, louisiana, mississippi, nevada (clark county only), oklahoma, south carolina and texas, can develop cracks in the fuel…
Remedy: Dealers will install a brace assembly at the strap bolt hole location and replace the tank strap with a revised, longer strap. Dealers will also inspect the tanks for leaks.
NHTSA investigations
Fuel tank fatigue cracking
See attached report.
Fuel tank cracks
There is no summary currently available
Fuel tank cracks
There is no summary currently available
Frequently asked questions
Which Ford Windstar years have fuel system problems?
By NHTSA complaints, the 1995 (148), 1998 (71), 1996 (52), 2000 (33) and 1999 (29) model years. Fuel System complaints make up 4% of all complaints for the 1995.
Is there a recall for Ford Windstar fuel system problems?
Yes — 2 recalls, including 00V-164 (delivery, Jun 19, 2000); 99V-309 (tank assembly, Nov 2, 1999). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Ford Windstar fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 90,000 miles; 15% happened before 50,000 miles.
What part fails most often?
Owners most often name the storage › tank assembly (139 mentions), followed by the delivery › fuel pump (36).
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.