2003 FORD WINDSTAR Complaints

THIS VEHICLE HAS HAD ABS CONTROL UNIT PROBLEMS SINCE IT WAS THREE YEARS OLD IN 2006. THE CONDITION BEING DESCRIBED IS NOT TO BE CONFUSED WITH A PREVIOUS WINDSTAR RECALL INVOLVING A LEAKING BRAKE FLUID PRESSURE SWITCH (NHTSA ACTION #EA08021). THE FIRST OCCURRENCE WAS IN THE SPRING OF 2006 (ONE MONTH OR A FEW THOUSAND MILES AFTER WARRANTY EXPIRATION) WHEN I WAS ABOUT 200 MILES FROM HOME ON A TRIP DRIVING UP INTERSTATE 91 IN MA IN THE RAIN. GLANCED DOWN AT DASH DISPLAY AND SAW BOTH THE BRAKE SYSTEM WARNING AND ABS SYSTEM WARNING LIGHTS ON. I STOPPED TO CHECK THE BRAKE FLUID. WHEN THE CAR WAS TURNED OFF AND RESTARTED, THE WARNING LIGHTS TURNED OFF. THAT WAS 6 YEARS AGO AND THE PROBLEM CONTINUED TO PROGRESS TO AN EXTREMELY PREDICTABLE PATTERN. IN WARM WEATHER, (OVER 40 DEGREES F), THE ABS SYSTEM WILL NOT FUNCTION AND THE WARNING LIGHTS ARE ON. WHEN WINTER COMES, THE WARNING LIGHTS GO AWAY AND THE ABS WORKS NORMALLY. I WAS TOLD BY DEALER THAT IT WOULD BE A $700 REPAIR. SINCE THE SYSTEM WORKED IN THE WINTER (WHEN I NEED THE ABS THE MOST) AND HAD SPENT A LOT OF MONEY ON SEVERAL OTHER ENGINEERING DEFECTS OF THIS CAR, I HAVE LIVED WITH THE PROBLEM. IT WAS MOSTLY AN ANNOYANCE. HAVING DONE SOME RESEARCH THOUGH, I HAVE FOUND THAT THERE ARE MANY OTHER WINDSTARS WITH IDENTICAL SYMPTOMS AND THEY CENTER ON A DEFECT OF THE ABS MODULE DESIGN. AFTER THE MODULE HAS BEEN CYCLED THERMALLY FOR HUNDREDS OF TIMES IN SERVICE (HEATING, COOLING, HEATING, COOLING, ETC.) THERE ARE SOLDER CONNECTIONS ON THE PCB THAT ARE NO LONGER RELIABLE AND BECOME INTERMITTENTLY CONNECTED. IT BASICALLY IS AN ELECTRICAL OR MECHANICAL ENGINEERING 101 TOPIC KNOWN AS TCE (THERMAL COEFFICIENT OF EXPANSION) MISMATCH. MY CONCERN NOW IS THAT THE FAILURE IS PROGRESSIVELY GETTING WORSE AND EXTENDING FURTHER IN TO THE COLD WEATHER PERIOD. ANY DESIGN ISSUE WITH A BRAKE SYSTEM OR COMPONENT IS A SERIOUS SAFETY ISSUE. *TR

ABS BRAKES DASHBOARD LIGHT AND CHECK ENGINE LIGHT IS ALWAYS ON. DEALER HAS RESET MANY TIMES WITH NO SUCCESS. *TR

ABS WARNING LIGHT COMES ON INTERMITTENTLY. ABS SYSTEM DOES NOT WORK. BRAKE WARNING LIGHT USUALLY COMES ON SIMULTANEOUSLY. *TR

TL* THE CONTACT OWNS A 2003 FORD WINDSTAR. THE CONTACT STATED THAT WHILE DRIVING 20 MPH OVER A ROAD BUMP, THE VEHICLE EXHIBITED AN ABNORMAL NOISE. THE CONTACT LATER NOTICED THAT THE AXLE WAS FRACTURED AND RUSTED. THE VEHICLE WAS TOWED TO A MECHANIC FOR INSPECTION WHERE THEY STATED THAT THE AXLE WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND THEY STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 12V193000 (POWER TRAIN:AXLE ASSEMBLY). THE FAILURE MILEAGE WAS 56,000.

ABS AND BRAKE LIGHT COMES ON AND OFF, DRIVERS SIDE WINDOW AND REAR DRIVERS SIDE WING DOES NOT OPERATE PROPERLY, RADIO CHANGES STATIONS ON ITS OWN, ENGINE SERGE WHEN IN IDEAL, INTERIOR LIGHTS COME ON BY THEMSELVES, NOISE IN REAR WHEN IN REVERSE. *TR

THE RUBBER ON THE WIRES GOING TO THE POWER DISTRIBUTION BOX RUBBED OFF AND MELTED SHORTING OUT EVERYTHING. CASED THE SPEEDOMETER TO GO OUT TACHOMETER TO STOP WORKING ABS AND BRAKE LIGHTS TO COME ON AND OVERDRIVE LIGHT BLINKS. MAY HAVE COT ON FIRE FOR A MIN I SMELLED SMOKE BUT WENT OUT ON ITS OWN. *TR

ABS AND BRAKE LIGHTS CAME ON, LIGHTS GO OFF IF CAR IS TURNED OFF FOR A MINUTE. SPORADIC PROBLEM THAT DOESN'T FOLLOW A PATTERN. *TR

TL* THE CONTACT OWNS A 2003 FORD WINDSTAR. THE CONTACT STATED THAT THE SUB-FRAME EXHIBITED A HOLE DUE TO RUST AND CORROSION. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THE CONTACT WAS ADVISED THAT THERE WAS A HOLE IN THE SUB-FRAME. THE DEALER WAS NOTIFIED OF THE FAILURE WHO THEN ADVISED THAT THERE WERE NO RECALLS FOR THE SUB-FRAME. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE WHO FILED A COMPLAINT FOR THE CONTACT. THE FAILURE MILEAGE WAS 139,379.

ABS AND BRAKE WARNING LIGHTS CAME ON AFTER DRIVING APPROXIMATELY 3 MILES AND STAYED ON. *TR

TL* THE CONTACT OWNS A 2003 FORD WINDSTAR. THE CONTACT STATED THAT WHILE PARKED THE TRACTION CONTROL, ABS, AND EMERGENCY BRAKE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO TWO DIFFERENT INDEPENDENT MECHANICS FOR DIAGNOSTIC TESTING WHO WERE UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 98,000.