I took my 2001 Windstar sel into a dealership upon receiving a recall notice for suspension:rear:axle:non-powered axle assembly in March of 2011. Our vehicle passed this inspection. At the time our vehicle was at the dealership for this recall notice there was another recall relating to structure: Frame and members:underbody shields although we were unaware of this recall. We have not received a recall notice about the second problem to date. The recall was brought to our attention by a friend who watched a news program regarding the recall which prompted a phone call to the dealership that serviced our vehicle in March. His statement was if our vehicle was one of the recalled vehicles and it was just in the service department for another recall the service technician would have addressed the most recent recall also. He asked for our VIN which at the time was not available but reassured me both recalls would have been addressed since they were both open recalls. On August 1, 2011 I was driving at 65-70 mph on a freeway when my steering wheel started to jerk and turn counter-clockwise (the last time I looked at the steering wheel the area that encloses the horn was vertical). I thought my right passenger wheel was punctured at first but knew it was more than that within the next few seconds. Something from the van kept hitting the freeway and jerking me around and the back end of the van on three occasions seemed like it was coming off the ground. Once I slowed down enough the safely brake that is exactly what I did wherein the rear end of the vehicle jerked to the left. I exited the vehicle and called 911. Not only did the subframe break due to rust but the axle came apart from the vehicle as did the right arm holding the wheel in place. At this point the dealership where the car was towed to said Ford is offering to replace the subframe and have offered to pay for two days for a rental vehicle.

- Madison, OH, USA

The contact owns a 2001 Ford Windstar. The contact stated that while driving approximately 25 mph and entering onto the interstate, the subframe from the engine separated from the vehicle. She then lost control of the vehicle and was unable to stop until the vehicle coasted to a stop. The vehicle was towed to an independent mechanic who informed the contact that the lower control arm mount had rusted out causing separation of the arm of the axle. The vehicle was repaired. The failure mileage was approximately 103,000. Updated 03/24/11

- Zion, IL, USA

2001 Ford Windstar 280,000 miles ne oh 10-11-10. Right side lower control arm separated from frame. 65 mph from left lane crossed 3 lanes rush hour traffic. No warning signs somehow no collision. Axle pulled from transmission. Replaced: Tire, axle, boots. Frame shop reinforced and straight frame, aligned front end. Repair damaged transmission cooling lines and required replacement.

- Warren, OH, USA

While switching from rear drive to forward drive, big noise was heard. Unable to drive car after due to front wheel suspension break, passenger side. Front suspension was replaced.

- Montreal, 00, USA

The front end of my 2001 Ford Windstar makes a lot of noise like it is going to fall apart. I'm afraid because my rear axle broke in 2 pieces going 65 mph on the interstate. I'm sure something is going on with my front subframe. How do we get this investigated?

- Red Oak, IA, USA

We had just left the expressway. We pulled into a parking lot and went to turn into a parking space and the shaft which was attached to the wheel connecting it from the frame to the wheel, broke at the point of the factory weld causing the wheels to do the "splits"and pulling out the driveshaft from the transmission. The dealer called the car "totalled".this car is in great condition except for the metal socket holding the tie rod from the wheel to the frame allowing the drive shaft to be yanked out. This is a factory weld that broke and if it had broken while on the freeway, we could have been killed. Ford motor refused to do anything to remedy the situation.

- Southfield, MI, USA

I own a 2001 Ford Windstar that I recently had the subframe replaced as it had corroded through on the right side of the subframe. I noticed the failure of it while driving. I heard a loud clunk and then my steering wheel abruptly turned to the right and the front end started vibrating similar to when the front end is out of alignment. I was traveling at a low rate of speed when this occurred and id not result in a crash, but made the vehicle undriveable.

- Reedsburg, WI, USA

The front sub-frame on the right side has severe rusting and corrosion where the sub-frame meets the control arm. I took it in for inspection and was notified by the mechanic that it would not pass without replacement and was not even safe to drive out of his shop. He also said that he was surprised the car passed inspection at the Ford dealership last year. Thankfully, it was discovered before the sub-frame detached.

- Langhorne, PA, USA

The subframe is rusting and corroding where the control arm attaches to it. My vehicle will not pass inspection. I have researched this online and have learned that NHTSA is investigating this on the Ford Windstar.

- Portsmouth, NH, USA

While driving my 2001 Ford Windstar on M-20 near remus, mi I heard a loud boom from the front of the vehicle. I pulled off of the road to investigate and found the driver side front coil spring broken. I had to replace the spring and strut assembly on that side. I was told that I should replace the other side as well. Both front spring/strut assemblies were replaced at my personal cost.

- Stanwood, MI, USA

Clunking noise from R/F of vehicle when turning left, and severe pull when accelerating. Found front subframe rusted thru and cracked at passenger side rear mount. Had to replace front subframe.

- Doylestown, PA, USA

The contact owns a 2001 Ford Windstar. While driving approximately 1 mph, the contact heard a loud bang and the vehicle would no longer accelerate. Upon examining the vehicle, the contact noticed that the front passenger side wheel was pointed in the opposite direction of the front driver side wheel. The vehicle was towed to the contact's residence; it had not been inspected or repaired. The current and failure mileages were approximately 132,000. The consumer stated even before the vehicle was towed the garage, he could see that the bracket that held the lower control arm to the frame had completely broken off the frame. When the control arm lost that attaching point, the wheel was allowed to pull away and also pulled the axle shaft away from the transmission. The subframe and transmission seal had to be replaced. Updated evoq 02/15/11

- Livonia, NY, USA

I was driving a 2001 Ford Windstar minivan with 154K miles on a rainy night at highway speed on a 3 lane interstate with 5 children aboard. I heard a loud noise from the vehicle and lost all control as the steering and braking wasn't working right. As I tried to get onto the shoulder, it kept swerving toward the left, back into the lanes. When it finally stopped moving, we were sticking out into traffic and I feared we would be hit. The tow truck driver showed me that the right tire wasn't even pointing straight ahead anymore and said that the axel probably broke. The mechanic told me that the frame cracked and in his opinion, he wouldn't recommend fixing the vehicle. The insurance company said the right front lower control arm mount rotted off which pulled out axel and broke tie rod end and so on, due to normal wear and tear. I received zero dollars for my auto claim and my family of seven had to use our 3 seater pickup truck as the family vehicle for months after the incident. I live in a snow belt state and I do not believe that normal wear and tear occurred in a mere 8 years. I have pictures of the vehicle after the incident as well. Thank you for the opportunity to provide information for open investigation #PE10-026. My hope is that my story is useful enough to help prevent this same thing from happening to other 2001 Ford Windstar owners.

- Mansfield, CT, USA

I have a 2001 Ford Windstar which is showing signs of a sub-frame corrosion failure similar to the one described in investigation pr 10-026. There is a "U-shaped" subframe element which connects to the main frame near the outboard side of both front seats and extends forward around the front of the car. It does appear various suspension and steering members are connected to this sub-frame. The passenger-side end of this sub-frame where it connects to the vehicle frame shows severe rusting and metal delamination and a crack has formed on the end. The driver-side end of this subframe shows normal wear and is not in immediate risk of failure. The corrosion to the passenger-side end is excessive as compared to the driver's side and other frame elements in the vicinity. Something is accelerating the corrosion on the right side. It may be due to the condensate drain from the air-conditioning system. At this time, the sub-frame has not failed but the vehicle represents a significant safety risk since failure-related crashes have been reported. The repair costs are estimated to be in excess of $2000 for frame replacement. I believe that Ford should quickly develop and deploy a means of reinforcing the frame member and offer the repair via recall to Windstar owners. Since the parts are currently still on my vehicle, I can take photographs showing the deterioration of the sub-frame ends. As a side note: My Windstar is equipped with the rearseat air-conditioning system. The evaporator is in the rear quarter-panel on the driver's side in the rear or the vehicle. While this affected components do not appear to be a critical part of the vehicle's structure, there is significant corrosion to the parts which are in the path of the condensate drain for the rear A/C system as well. This seems to confirm the belief that A/C condensate run-off is a key factor in the sub-frame corrosion issue.

- Utica, NY, USA

Failure/braking of the front coil springs.

- Wallingford, CT, USA

My husband was backing out of the driveway at work, when the tires were turned inward because of the break in the rear axle. After having it towed my husband bought a rear axle from another vehicle and replaced the broken one.

- Apollo, PA, USA

Failure of bracket holding upper control arm to frame on 2001 Ford Windstar with 58,000 miles on the odometer. Failure caused wheels to go their own way causing total lack of control of vehicle.

- Mount Vernon, ME, USA

While driving on interstate the passenger side front lower control arm broke loose from the frame causing total loss of vehicle control. Van has 60K miles and was well maintained

- Delanson, NY, USA

The mounting ears on the right front subframe (H-frame that all the suspension, steering, and drivetrain) that connects the lower control arm to the frame rotted off the frame allowing the passenger side tire assy. To swing out from under the vehicle causing a loss of control. Fortunately it happened when turning left at a intersection and not on the freeway. The whole front H frame has to be replaced. The vehicle is an 01 Ford Windstar with approx. 61,000 miles, always taken good care of and garage kept. Original owner never any accidents.

- Livonia, MI, USA

Coil spring on passenger side strut broke, has driver's side break the year before, had to replace whole strut / spring assembly, could've caused accident if the pieces would have hit the tires instead of wrapping around rest of spring.

- Rittman, OH, USA