1996 Ford WINDSTAR: complaints, problems and recalls

PROBLEM WITH 1996 FORD WINDSTAR 3.8L ENGINE 45,000 MI. W/ DEFECTIVE HEAD GASKET. FORD EXTENDED THE WARRANTY ON 94-95 MODELS BUT WON'T COVER 96 MODELS. THIS IS A KNOWN PROBLEM W/ ALL THE 3.8L ENGINES AND FORD SHOULD BE HELD RESPONSIBLE FOR MANUFACTURING AND SELLING A DEFECTIVE PRODUCT. A RECALL SHOULD BE DONE ON THIS PRODUCT. TS

Owner-reported narrative. 45,054 miles reported. Look up ODI 10000514 at NHTSA ↗

WHILE DRIVING AND WITHOUT WARNING HEAD GASKET/TIMING CHAIN SNAPPED, CAUSING FLUID TO LEAK. DEALER NOTIFIED. TS. *AK

Owner-reported narrative. Look up ODI 10001803 at NHTSA ↗

CONSUMER STATES THAT SPEEDOMETER DOES NOT FUNCTION PROPERLY. THE NEEDLE MOVES ERRATICALLY AND MAKES A TICKING NOISE. CONSUMER IS UNABLE TO ASCERTAIN CORRECT SPEED WHILE DRIVING. DEALER HAS UNSUCCESSFULLY ATTEMPTED TO REPAIR 2 TIMES BY REPLACING SPEEDOMETER CABLE. TS

Owner-reported narrative. Look up ODI 10001902 at NHTSA ↗

CONSUMER STATES WHILE DRIVING 2MPH STEERING COLUMN STARTED SMOKING,THEN DRIVER SIDE AIRBAG DEPLOYED IN CONSUMER FACE. TS

Owner-reported narrative. Look up ODI 10002214 at NHTSA ↗

CONSUMER STATED THAT WHILE DRIVING THE FRONT COIL SPRINGS PUNCTURED THE DRIVER'S FRONT TIRE ALMOST RESULTING IN VEHICLE CRASHING. *NLM

Owner-reported narrative. Look up ODI 10002428 at NHTSA ↗

I WOULD LIKE TO FILE A COMPLAINT REGARDING MY 1996 FORD WINDSTAR. I HAVE JUST LEARNED THE HEAD GASKET ON MY VEHICLE HAS BLOWN OUT WITH JUST 70K MILES ON IT. I KNOW FORD RECALLED 1995 MODELS AND AFTER SOME RESEARCH OF MY OWN, HAVE LEARNED THAT THERE ARE JUST AS MANY 96'S WITH THE SAME PROBLEM AND FORD REFUSES TO DO ANYTHING WITH THAT MODEL YEAR.

Owner-reported narrative. 60,000 miles reported. Look up ODI 10002728 at NHTSA ↗

TRANSMISSION FAILURE IN 1996 FORD WINDSTAR, REQUIRING COMPLETE REPLACEMEN AT APPROX 70K MILES

Owner-reported narrative. 70,000 miles reported. Look up ODI 10003256 at NHTSA ↗

THE VEHICLE ROLLED BACK WITH THE GEAR IN THE PARKING POSITION ON THE DRIVE WAY

Owner-reported narrative. 80,000 miles reported. Look up ODI 10003546 at NHTSA ↗

Reported: 2000-06-19 (June 19, 2000)

VEHICLE DESCRIPTION: MINI VANS, LIGHT PICKUP TRUCKS, AND SPORT UTILITY VEHICLES. OFF LEASE CANADIAN VEHICLES EQUIPPED WITH DAYTIME RUNNING LIGHTS WHICH MEET CANADIAN REQUIREMENTS AND NOT THE PHOTOMETRIC REQUIREMENTS OF FMVSS 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." ACCORDING TO FORD, THE VEHICLES WERE IMPORTED INTO THE U.S. ERRONEOUSLY.

Consequence: THE LIGHT GIVEN OFF FROM THE DAYTIME RUNNING LIGHTS IS BRIGHTER THAN ALLOWED BY U.S. STANDARDS.

Remedy: DEALERS WILL BE ADVISED TO DEACTIVATE THE RUNNING LIGHT FUNCTION AND TO COMPLETE ANY OUTSTANDING SAFETY RECALLS ON THESE VEHICLES.

Reported: 2002-04-04 (April 4, 2002)

ON CERTAIN MINIVANS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. DURING ASSEMBLY, SOME BRAKE LINES WERE INSTALLED IN A TWISTED POSITION, CAUSING CONTACT WITH THE DASH PANEL INSULATOR ABOVE THE CATALYTIC CONVERTER. THIS CONTACT COULD ABRADE THE BRAKE LINE CORROSION PROTECTION, CONSEQUENTLY, SALT OR WATER ABSORBED IN THE DASH PANEL INSULATOR WOULD PROMOTE CORROSION. THIS CORROSION COULD ULTIMATELY LEAD TO A LEAK IN THE BRAKE LINE.

Consequence: LEAKAGE OF BRAKE FLUID WILL RESULT IN BRAKE LIGHT ACTIVATION. EXTENDED STOPPING DISTANCE COULD ALSO RESULT, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT THE BRAKE LINE FOR CORROSION AND CLEARANCE CONDITIONS. A BRAKE LINE THAT IS NOT CORRODED WILL BE REPOSITIONED. A BRAKE LINE THAT IS CORRODED OR LEAKING WILL BE REPLACED WITH A NYLON COATED BRAKE LINE AND SECURED USING THREE RETAINING CLIPS TO ASSURE CLEARANCE FROM THE INSULATOR. OWNER NOTIFICATION BEGAN MAY 10, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.

Reported: 2009-10-13 (October 13, 2009)

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

Reported: 1996-05-14 (May 14, 1996)

THE PARK PAWL SHAFT WAS IMPROPERLY POSITIONED WHEN THE ROLL PIN THAT RETAINS IT WAS INSTALLED DURING TRANSMISSION ASSEMBLY. IF THE SHAFT WAS NOT PROPERLY POSITIONED, THE ROLL PIN MAY NOT HAVE LINED UP WITH THE GROOVE IN THE SHAFT AND HAVE BEEN CRUSHED AT ASSEMBLY. ALSO, A BURR COULD HAVE BEEN RAISED ON THE SHAFT.

Consequence: THIS COULD RESULT IN THE PARK PAWL OCCASIONALLY NOT ENGAGING WHEN THE TRANSMISSION SELECTOR LEVER IS PLACED IN THE PARK POSITION. THIS COULD RESULT IN THE VEHICLE ROLLING AS IF IN NEUTRAL IF THE VEHICLE OPERATOR DOES NOT APPLY THE PARKING BRAKE.

Remedy: DEALERS WILL INSPECT THE PARK PAWL SHAFT ROLL PIN. IF THE ROLL PIN IS DAMAGED, BOTH THE ROLL PIN AND THE PARK PAWL SHAFT WILL BE REPLACED. IN ADDITION, OWNERS WILL BE REMINDED TO FULLY APPLY THE PARKING BRAKE, IN ADDITION TO PLACING THE TRANSMISSION IN PARK.

Reported: 1996-07-01 (July 1, 1996)

THE FOUR FASTENERS SECURING THE DRIVER'S SEAT TO THE FLOORPAN WERE NOT TORQUED TO PROPER SPECIFICATIONS.

Consequence: THE DRIVER'S SEAT MAY NOT PROPERLY HOLD IN THE EVENT OF A VEHICLE ACCIDENT RESULTING IN PERSONAL INJURY TO THE OCCUPANT.

Remedy: DEALERS WILL INSPECT THE DRIVER'S SEAT FASTENERS AND RETORQUE TO PROPER SPECIFICATIONS.

Reported: 1996-09-05 (September 5, 1996)

THE PARK PAWL ABUTMENT BRACKET HAS A SHARP EDGE WHICH CAN CAUSE THE PARKING PAWL TO HANG UP AND NOT ENGAGE THE PARK GEAR. THIS WOULD ALLOW THE VEHICLE TO MOVE EVEN THOUGH THE GEAR SHIFT INDICATOR SHOWS THAT THE VEHICLE IS IN PARK.

Consequence: UNINTENDED AND UNEXPECTED VEHICLE MOVEMENT CAN RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE PARK PAWL ABUTMENT BRACKET.

Reported: 1997-10-20 (October 20, 1997)

VEHICLE DESCRIPTION: PASSENGER VEHICLES AND MINI VANS. TEARING OF THE BOND BETWEEN THE INNER AND OUTER HOOD PANELS DURING MINOR FRONT END COLLISIONS CAN RESULT IN A GAP AT THE LEADING EDGE OF THE HOOD. AIR FORCED BETWEEN THE INNER AND OUTER PANELS CAN PRODUCE ENOUGH PRESSURE TO FORCE THE OUTER PANEL UPWARD.

Consequence: THIS CONDITION CAN RESULT IN TOTAL SEPARATION OF THE OUTER HOOD PANEL.

Remedy: DEALERS WILL INSPECT THE HOOD AREA FOR ANY DAMAGE ALONG THE LEADING EDGE OF THE HOOD. IF THERE IS ANY EVIDENCE OF BOND SEPARATION, THE HOOD WILL BE REPLACED. IF THERE IS NO EVIDENCE OF BOND SEPARATION, ADDITIONAL ADHESIVE WILL BE APPLIED BETWEEN THE INNER AND OUTER HOOD PANELS.

Reported: 1999-06-14 (June 14, 1999)

VEHICLE DESCRIPTION: MINIVANS. THE BRAKE FLUID MASTER CYLINDER IS RECESSED AND ORIENTED IN THE ENGINE COMPARTMENT SO THAT THE BRAKE FLUID WARNING STATEMENT EMBOSSED ON BOTH THE TOP OF THE FILLER CAP AND THE SIDE OF THE RESERVOIR BODY ARE NOT ENTIRELY VISIBLE BY DIRECT VIEW. THESE VEHICLES MAY NOT FULLY COMPLY WITH REQUIREMENTS OF FMVSS NO. 135, "PASSENGER CAR BRAKE SYSTEMS."

Remedy: OWNERS WILL BE PROVIDED WITH NEW LABELS AND INSTALLATION INSTRUCTIONS.