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2002 Ford Windstar: problems, recalls and fuel economy
NHTSA has 1,353 owner complaints on file for the 2002 Windstar, led by brakes, suspension and the electrical system[1][2][3][4]. It also has 8 recalls, including rear axle and front control arm corrosion repairs and a fire risk in the speed control switch[5][6][7][8].
Most reported problems
Owners filed 1,353 complaints with NHTSA[1]. Of those, 45 mention a crash, 48 a fire and 53 an injury, and one reports a death[1]. These are unverified reports, and one complaint can name more than one component.
| Component group | Complaints | Median miles at failure |
|---|---|---|
| Brakes[2] | 563 | 97,000 |
| Suspension[3] | 279 | 132,750 |
| Electrical system[4] | 261 | 100,000 |
| Speed control[10] | 147 | 92,500 |
| Structure[11] | 101 | 114,356 |
| Power train[12] | 97 | 113,400 |
Brakes. This is the largest group, with 8 crashes and 18 fires among its complaints[2]. In a sample of complaints we read, owners describe dash warning lights for the brakes or ABS, and worn pads and rotors or a shaking steering wheel when braking[2].
Suspension. In the sample we read, owners describe a cracked or broken rear axle in half of the 12 texts, and some describe broken coil or leaf springs that damaged a tire[3]. The suspension group lists 7 crashes[3].
Electrical system. This group has 19 fires, the highest fire count of any group[4]. In the sample we read, owners describe power doors, locks and windows that work only some of the time, including sliding doors, and two describe a fire[4].
Speed control. In the sample we read, owners describe the van surging, lurching or speeding up when they did not expect it, and some blame the cruise control switch for wiring or brake fluid trouble[10]. The group lists 13 fires[10].
The power train group has the one reported death[12].
Recalls
NHTSA lists 8 recalls for this model year[5]. Newest first:
- Rear axle brackets (15V608). Earlier axle repairs may have used brackets that were installed wrong. If so, the rear axle could break and hurt handling, raising crash risk. Dealers inspect the brackets and replace the axle if one was misinstalled, free of charge. The fix began in October 2015[13].
- Rear axle corrosion, Virginia (12V193). Corrosion can weaken the rear axle and crack it. A broken axle affects handling and raises crash risk. Dealers inspect and add reinforcement brackets or replace the axle, free of charge. The recall covers vehicles registered or first sold in Virginia[14].
- Front control arm, Virginia (12V194). Corrosion can break the control arm bracket or body mounts. That could cause a significant loss of steering control. Dealers inspect and repair free of charge. The recall covers vehicles first sold or registered in Virginia[7].
- Rear axle, Puerto Rico (12V195). Repeated twisting loads can crack the rear axle. A broken axle can cause loss of control. Dealers inspect and add a bracket or replace the axle, free of charge. The recall covers vehicles registered in Puerto Rico[15].
- Underbody and control arm (11V030). A front lower control arm bracket or the front subframe body mounts can separate, which can reduce steering control. Dealers inspect and repair free of charge. If a repair cannot be made, Ford offers to buy the vehicle back. The recall covers vehicles sold or registered in a list of states[16].
- Rear axle corrosion (10V385). Corrosion can weaken the rear axle and crack it, affecting handling. Dealers inspect and, if needed, install reinforcement brackets free of charge. This recall lists certain states[6].
- Speed control switch (09V399). A leaking switch can overheat, smoke or burn, and a fire could start even with the engine off. Dealers add a fused wiring harness and, on some Windstars, check the ABS module connector, free of charge[8].
- Seat latches (03V459). A third row latch let go in testing before it met the strength requirement, and the same latch is used in the second row. In a crash this raises injury risk. Dealers replace the second and third row seat-to-floor latches[17].
Several recalls apply only to certain states or Puerto Rico. Ask Ford or a dealer whether a specific van is covered.
Fuel economy
EPA rates the Windstar at 16 mpg city, 21 highway and 18 combined[9]. That figure is for the 3.8L 6-cylinder engine with a 4-speed automatic, regular fuel and front-wheel drive[9]. It is the same for the cargo van[9] and the wagon[18].
EPA estimates annual fuel cost at $3,700[9][18]. That estimate uses EPA's current fuel price assumptions, not prices when the van was new.
Safety ratings
NHTSA's 5-Star Safety Ratings list this model year as not rated[19][20]. Recall and complaint history are the safety information we have.
Engine and size
EPA lists a 3.8L 6-cylinder engine with a 4-speed automatic[9][18]. Dimensions below are Canadian-market specifications for the LX, Sport, SEL and Limited and can differ slightly from US vans[21].
How 2002 compares with other years
Show the numbers
| Model year | Complaints | Recalls |
|---|---|---|
| 1995 | 3,326 | 6 |
| 1996 | 1,386 | 8 |
| 1997 | 192 | 5 |
| 1998 | 1,433 | 11 |
| 1999 | 1,522 | 11 |
| 2000 | 1,675 | 15 |
| 2001 | 1,686 | 15 |
| 2002 | 1,353 | 8 |
| 2003 | 1,510 | 8 |
Among the nine Windstar model years on file, 2002 has the second-lowest complaint count at 1,353[5]. Only 1997 has fewer, at 192[5]. The 1996 year is close at 1,386, and 2000 and 2001 have 1,675 and 1,686[5].
For recalls, 2002 has 8, the same as 1996 and 2003[5]. Model years 1998 and 1999 have 11 each, and 2000 and 2001 have 15 each[5]. Years 1995 and 1997 have fewer, with 6 and 5[5]. Complaint counts are not adjusted for how many vans were sold, so use them as a rough guide only.
Should you buy a used 2002 Windstar?
The file for this year is mixed. Complaint and recall counts are lower than for several other Windstar years[5], but the complaints are still concentrated in brakes, suspension and electrical parts[2][3][4]. Rear axle cracking appears in both the recalls and the complaint sample we read[13][6][3]. If you are shopping, ask for proof that the recalls covering that van were done, and have the rear axle, front suspension and brakes inspected. Check fuel costs too, since EPA's estimate is $3,700 a year[9].
Frequently asked questions
- What are the common problems with the 2002 Ford Windstar?
- NHTSA lists 1,353 complaints[1]. The largest groups are brakes with 563, suspension with 279 and the electrical system with 261[1][2][3][4].
- How many recalls does the 2002 Ford Windstar have?
- NHTSA lists 8[5], covering rear axle corrosion, front control arm and subframe mount problems, a speed control switch fire risk and seat latches. Some apply only to certain states[5][13][7][16][8][17].. Some apply only to certain states[5][13][16][8][17].
- What is the gas mileage of a 2002 Ford Windstar?
- EPA rates it at 16 city, 21 highway and 18 combined mpg[9][18].
- Is the 2002 Windstar a better year than other Windstars?
- It has the second-lowest complaint count of nine years, 1,353, behind only 1997 at 192, and 8 recalls compared with 15 in 2000 and 2001[5].
Facts and sources
- NHTSA has 1,353 owner complaints on file for the 2002 Ford Windstar (45 mention a crash, 48 a fire, 53 injuries, 1 deaths reported). NHTSA vehicle records
- 563 complaints name the brakes component group (8 crashes, 18 fires, 3 injuries, median mileage at failure 97,000). NHTSA vehicle records
- 279 complaints name the suspension component group (7 crashes, 7 fires, 4 injuries, median mileage at failure 132,750). NHTSA vehicle records
- 261 complaints name the electrical system component group (2 crashes, 19 fires, 1 injuries, median mileage at failure 100,000). NHTSA vehicle records
- Owner complaints and recalls for every Ford Windstar model year (chart above). NHTSA recall database
- Recall 10V385, filed August 26, 2010: Suspension › Rear › Axle › Non-Powered Axle Assembly. NHTSA recall database
- Recall 12V194, filed May 3, 2012: Suspension › Front › Control Arm. NHTSA recall database
- Recall 09V399, filed October 13, 2009: Vehicle Speed Control. NHTSA recall database
- EPA rating for Windstar FWD Cargo Van, 3.8L 6-cyl, Automatic 4-spd, Regular, Front-Wheel Drive: 16 city / 21 highway / 18 combined MPG; EPA estimated annual fuel cost $3,700. EPA / DOE fueleconomy.gov
- 147 complaints name the speed control component group (4 crashes, 13 fires, 5 injuries, median mileage at failure 92,500). NHTSA vehicle records
- 101 complaints name the structure component group (7 crashes, 0 fires, 8 injuries, median mileage at failure 114,356). NHTSA vehicle records
- 97 complaints name the power train component group (6 crashes, 1 fires, 2 injuries, median mileage at failure 113,400). NHTSA vehicle records
- Recall 15V608, filed September 29, 2015: Suspension › Rear › Axle › Non-Powered Axle Assembly. NHTSA recall database
- Recall 12V193, filed May 3, 2012: Power Train › Axle Assembly. NHTSA recall database
- Recall 12V195, filed May 3, 2012: Suspension › Rear › Axle › Non-Powered Axle Assembly. NHTSA recall database
- Recall 11V030, filed January 26, 2011: Structure › Frame And Members › Underbody Shields. NHTSA recall database
- Recall 03V459, filed November 6, 2003: Seats › Mid / Rear Assembly. NHTSA recall database
- EPA rating for Windstar FWD Wagon, 3.8L 6-cyl, Automatic 4-spd, Regular, Front-Wheel Drive: 16 city / 21 highway / 18 combined MPG; EPA estimated annual fuel cost $3,700. EPA / DOE fueleconomy.gov
- NHTSA 5-Star Safety Ratings, 4 DR None: not rated. NHTSA vehicle records
- NHTSA 5-Star Safety Ratings, W/SAB None: not rated. NHTSA vehicle records
- Transport Canada specifications via NHTSA vPIC, WINDSTAR LX/SPORT/SEL/LTD: length 201 in, width 76 in, height 68 in, wheelbase 121 in, curb weight 3,891 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov