While driving on X way appox. 60 mph, noticed smoke emitting from rear of car and begin hearing a clicking sound. As I was pulling car over to side the right rear tire suddenly deflated. Tow truck was called, upon loading of vehicle on bed of truck was able to see rear axle in the middle toward passenger side had rusted thru right in the middle of a bracket Ford had installed in 2011 due to a recall. Was informed that in 2015-16 Ford did another recall on the bracket not being improperly installed. As showed in the attached photo there is only one bracket installed, my understanding there should be two. But even then that does not resolved the rust problem, it just holds the axle when it does break or corrode thru.

- Detroit, MI, USA

The contact owns a 2002 Ford Windstar. While driving 45 mph, the vehicle felt as if it shifted into neutral. There were no warning indicators illuminated. The contact coasted the vehicle over to the side of the road and powered off the engine. The vehicle was restarted, but failed to drive. The vehicle was towed to the contact's residence where an independent mechanic diagnosed that the torque converter failed and needed to be replaced. The vehicle was not repaired. The contact called gary crossley Ford at (816) 781-4844 (located at 8050 N church rd, Kansas City, mo 64158) and was informed that the vehicle was not included in a recall. The vehicle was not taken to a dealer. The manufacturer was not notified of the failure. The approximate failure mileage was 200,000. Consumer stated 2002 Ford Windstar output shaft failed causing sudden loss of engine power without any warning which increased the risk of crash.

- Liberty, MO, USA

The contact owns a 2002 Ford Windstar. The contact stated that while driving approximately 35 mph, a loud noise was present coming from the rear of the vehicle. After stopping the vehicle it was discovered that both rear wheels were angled inward inside the wheel well. The vehicle was inspected by an independent mechanic who diagnosed that the rear axle had fractured. The cause of the failure was not determined and the vehicle was not repaired. The manufacturer was notified of the failure. The contact was informed that the vehicle was previously serviced in 2012 under the NHTSA recall campaign number: 12V193000 (power train) to prevent the failure from occurring. The local dealer was not notified. The VIN was not available. The failure mileage was 150,000.

- Greenfield, WI, USA

The rear axle broke at 45mph blowing out both rear tires thankgod we wern't hurt and had no cars behind us seen recall online called Ford but was told the van was not part of recall was purchased in mi new and has U design axle

- Lehigh Acres, FL, USA

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 (888) 397-9172 (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.

- Franklinville, NJ, USA

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. I have owned this vehicle less than 6 months and now as a single mom am left without a vehicle. I will never buy another Ford again in my life and I will also discourage my friends and family from purchasing Ford as well.

- Lancaster, PA, USA

2002 Windstar recall I was driving down the road one day to find out all off all the shifters but neutral the van suddenly had stopped going we could not go in drive reverse or anything find out stuck in middle of intersection with cars coming our way this problem is still unknown

- Shrlbyville, TN, USA

April 3, 2016 while in motion on busy highway (I-96), vehicle just stopped going under power and rolled to a dangerous stop. Vehicle had no drive power to wheels. Vehicle had to be towed. Examination indicates transmission issue. Vehicle does not engage any gears and made no warning sounds. Mechanic says torque converter failed and is a common problem. NHTSA recalled Ford freestar for this issue but Windstar are most effected and have not been recalled. On a highway, this is dangerous at 70 plus mph speeds. There was a family of four in this vehicle, when it just stopped going, with engine running. Someone can be killed in a rear-end collision from this warningless and sudden power-train failure. Vehicle has 108,900 miles and has undergone other recalls.

- Detroit, MI, USA

The contact owns a 2002 Ford Windstar. While driving various speeds, an abnormal odor and noise were noticed from the passenger side wheel. The vehicle moved in reverse when the gear shifter was in the drive position. The failure occurred constantly and the anti-brake warning light illuminated. The vehicle was not diagnosed nor repaired. The vehicle was serviced for NHTSA campaign number: 15V608000 (suspension). The manufacturer was not notified of the failure. The failure mileage was 356,078.

- Chicago, IL, USA

REAR AXLE REINFORCEMENT BRACKETS WERE INSTALLED IN MY FORD WINDSTAR UNDER SAFETY RECALL 10S13, BY AN AUTHORIZED FORD (DEALER'S) REPAIR SHOP IN 2011. I WAS TOLD BY THE FORD REPAIR SHOP THAT "BRACKETS" WERE THE ONLY TYPE OF REPAIR FORD AUTHORIZED THEM TO DO UNDER THAT RECALL NOTICE. I RECENTLY RECEIVED ANOTHER REAR AXLE RECALL NOTICE, 15S27, THAT SAID REPAIR BRACKETS IMPROPERLY INSTALLED UNDER THE PRIOR RECALL, MAY RESULT IN A REAR AXLE BEAM FRACTURE. THE RECALL NOTICE SAID IF AXLE REPLACEMENT WAS NECESSARY, FORD WOULD REPLACE IT FREE OF CHARGE. WHEN I TOOK MY CAR BACK TO THE SAME FORD REPAIR SHOP, THE SERVICE MANAGER SAID THAT THE REAR AXLE WAS INDEED CRACKED AND NEEDS TO BE REPLACED. HE ALSO SAID THAT FORD IS REFUSING TO REPLACE IT FREE OF CHARGE AND REQUIRES A COPAY OF $300. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD THE SAME THING. I BELIEVE THE "BAND AIDE" REPAIR ORIGINALLY AUTHORIZED BY FORD UNDER THE FIRST REAR AXLE RECALL, WAS INSUFFICIENT TO PREVENT STRESS POINTS IN THEIR DEFECTIVE REAR AXLE FROM CAUSING A SUBSEQUENT FRACTURE THAT NO AMOUNT OF PREVENTATIVE MAINTENANCE COULD DETER. I BELIEVE THE SECOND AXLE RECALL NOTICE INDICATES THAT FORD HAS PLACED THE PUBLIC IN JEOPARDY WITH "CHEAP FIXES" TO DEFECTIVE PARTS. HOWEVER, INSTEAD OF ETHICALLY REPLACING THE AXLE, FORD NOW SEEMS TO BE CUTTING THEIR LOSSES BY OFFERING A "DISCOUNTED" AXEL REPLACEMENT (ONLY) AT ONE OF THEIR AFFILIATED SHOPS. BECAUSE A REAR AXLE CAN COST ABOUT $1000 TO REPLACE, FORD'S "DISCOUNT" EFFECTIVELY STEERS THE BUSINESS OF CUSTOMERS WHO NEED THIS REPAIR INTO FORD'S CONTROLLED BUSINESS ENVIRONMENT. WE ARE LEFT WITH NO CHOICE BUT TO PAY FORD AGAIN, TO CORRECT THEIR ERROR AND KEEP US SAFE. PLEASE CALL ME AT [XXX] CAR IS CURRENTLY AT LUCAS FORD, BURLINGTON NJ. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

- Delanco, NJ, USA

The contact owns a 2002 Ford Windstar. The contact stated that while driving at 70 mph, the tire began to rub the inner fender wall. The vehicle was taken to the dealer where it was diagnosed that the axle was fractured and needed to be repaired. The vehicle was serviced under NHTSA campaign number: 11V030000 (structure) but the remedy failed to repair the vehicle. The contact mentioned that the axle should have been replaced initially under the recall and not bracketed. The manufacturer was made aware of the failure. The failure mileage was 140,000. Updated 12/03/15 updated 12/09/15.

- Dubuque, IA, USA

I am writing before I encounter a serious problem on the road. While in for state vehicle inspection, my mechanic noted that the rear axle "repair" (a reinforcement bracket) on my 2002 Windstar van is failing. It can look ok on the lift, but once weight is put on the axle, the seriousness of the cracking is apparent. The repair was made by a Ford dealership in 2011 under recall 10S13. I already spoke with Ford customer service, and they say there is nothing they can do because the recall was completed. I am now waiting to see if the dealership that made the repair can help to correct the problem they (Ford) have acknowledged exists, but without an adequate fix to date.

- Roslyn, PA, USA

My 2002 Windstar had the axle crack just under the recall repair sleeve the driver's side about a month ago. I brought it to the Ford dealer who confirmed it was cracked and got the same response as the others. Ford warrantied the repair for 12 months. I had the repairs done during the recall brackets were added to reinforce the axle. I called 1-8003923673 (Ford company) from direction from the local dealership. It appears that Ford put a band-aid on the problem and gave a 12 month warranty on it. That's ridiculous! it is obvious that they did not do an adequate assessment on these axles when they made the repair/replace decision. They knew about the axle problems in 1998. Stated in internal memo in 1999 that heat treating could double the axle life. It's shameful what they knew and what they ignored. I was told that since the recall repair was done over 12 months ago that it would not be covered.I being the only owner it should be a way to have this problem fix by Ford. I guess, I have not more choice to do the repair paying out of my pocket (not a chip repair) and to keep the receipt in case they expanded the recall. I also found out to go to NHTSA.gov to file a complaint. They will not expand the recall unless enough complaints are noted. Calling to the dealership is not enough. You have to call Ford co. 1-800-3923673 and visit NHTSA.gov before it is officially noted.

- Plainfield, NJ, USA

Total sudden loss of steering the car went off the road totally out of control. No notification of recall subframe collapse. Entire steering parts destroyed and coolant leaked from engine this is incredible that no one was injured I was about to get on the highway!!!

- West Nyack, NY, USA

I tool my 2002 Ford Windstar in for inspection of the rear axle and brackets were put in place. On March 9, the rear axle broke. Luckily it was as I was pulling into a parking spot at work. Ford is aware they have a manufactured defective part on these Windstar and yet after the bracket is place they refuse to replace the axle after is rust and breaks anyway. Ford deems it fixed. However, I disagree. They are putting the safety of thousands of people at risk. They should accept responsibility and repair the parts. Extremely unhappy. I have been calling Ford for 2 weeks and can not get a supervisor to return my call. It's ridiculous.

- Clinton Twp, MI, USA

After driving down a major highway North of boston, MA (128/95 North) my wife and I, first heard scraping noise that became louder and began smell like burning rubber/brakes. The car lurched across the roadway/highway and we swerved and almost sideswiped car in the adjacent lane. We were in the process of exiting the highway on the off ramp to my work at rte 28 South stoneham/wakefield. We were able to pull over, gather our thoughts and continue to a gulf station on rte 28 in stoneham, MA. The gulf station mechanic/manager said he had never seen anything like it, a rear axle literally splitting in half. After viewing the rear broken axle and looking at the condition of the front right end and the overall condition of the sub frame they politely and forgivingly said they have rarely seen such a thing (cracked/separated rear axle and went on to say they have only seen this in Ford Windstar and went on to talk about a local women whose Ford Windstar lost control on the highway at 60 mph with her 3 children and were scared to death and in conclusion would not touch the vehicle and warned that the vehicle was beyond safe driving and repair. They were shocked that although there was some kind of brace on the axle in two places that the axle had snapped in two at the reinforcement and said even without the reinforcement on the rear axle they have never seen a rear axle split in two and compounded with the fact that it actually had a reinforcement bracket fail. Reiterating axles and sub frames are not wear and tear parts and in fact had never seen broken rear axles and sub frames crack and break and corroded to this extent. Their reaction was of disturbing to say the least. They said broken axles just don, T happen and with added reinforcement it was "beyond belief" they had broken in half.

- Winchester, MA, USA

Our 2002 Ford Windstar's axle fractured, as described in NHTSA campaign id number 12V193000. The dealership had installed brackets in 2012, and respond that we are outside the twelve month coverage window on this work, and decline to do anything else for us. Can we be sure of the state of the axle on inspection in 2012? I think that since the axle fractured, they cannot assume they have no liability, or that their choice to install brackets instead of replacing the axle was sufficient.

- Beverly, MA, USA

We were driving around town and we heard a clunking sound in the back of the van. We took the van into the shop where they discovered a crack in the rear axle. Luckily this did not happen the week before, as we were driving many highway miles or it could have been worse. This was a recalled part and it was taken in at the time of the recall. Two different mechanics in town assured us that it was not our fault but that it was a faulty part. We take good care of our cars. We called Ford directly thinking that they would honor their vehicle and fix a part they knew would break down. They gave us the run around and then never returned our phone calls. This van would had many good years left in it, now it can not be driven!

- Stevens Point, WI, USA

Driving home, down country highway, vehicle had no noise or gave warning. Heard a loud hiss/noise, smoke screen appeared behind van, I coasted van off roadway. Had vehicle towed home. Upon checking, rod went thru engine and transmission casing. Am wondering if this has been a problem with this vehicle, because I heard of a similar incident just today with another Windstar. Thank you.

- Harrodsburg, KY, USA

The contact owns a 2002 Ford Windstar. The contact stated that the vehicle would exhibit a loud noise when started. The vehicle was inspected by an independent mechanic, who stated that the starter was hanging and the housing of the transmission was fractured. The contact was advised that the engine, starter motor and transmission needed to be replaced. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure and current mileage was 61,000.

- Fairlawn, NJ, USA