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2002 Ford Windstar Recalls, Problems & Maintenance

The 2002 Ford Windstar has no open NHTSA recalls. Owners report 5 recurring issue clusters, led by “ABS and brake warning lights illuminate intermittently.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Ford Windstar.

Reported to NHTSA

ABS and brake warning lights illuminate intermittently

SERVICE BRAKES

22 NHTSA complaints · 2015-04 → 2020-12

“YELLOW ABS LIGHT AND RED BRAKE LIGHT COME ON SIMULTANEOUSLY ON DASHBOARD IN INTERMITTENT AND RANDOM FASHION. HAS BEEN HAPPENING OVER EXTENDED PERIOD OF TIME - SOMETIMES OFF, OFTEN ON. AM INFORMED BY MY MECHANIC THAT WHEN THESE LIGHTS ARE ON, THE ABS BRAKING SYSTEM IS”
— Owner report, NHTSA ODI #10984349
“I GET A WARNING TO CHECK THE TRACTION CONTROL AND I GET A BRAKE MALFUNCTION WARNING, IT RESETS AFTER I TURN THE CAR OFF AND IT'S SPORADIC”
— Owner report, NHTSA ODI #10967895
“ABS LIGHT ON. TIRE ! LIGHT ON. RPM OFF SCALE”
— Owner report, NHTSA ODI #11101547

Read all complaints on NHTSA →

Torque converter failure with sudden loss of drive power

POWER TRAIN

4 NHTSA complaints · 2015-11 → 2019-01

“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”
— Owner report, NHTSA ODI #10853341
“TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. WHILE DRIVING AT APPROXIMATELY 50 MPH, THE VEHICLE DECELERATED AND FAILED TO ACCELERATE WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TORQUE CONVERTER NEEDED TO BE REPLACED. THE”
— Owner report, NHTSA ODI #10794694

Read all complaints on NHTSA →

Rear axle beam fracture after recall bracket repair

SUSPENSION

109 NHTSA complaints · 2015-04 → 2026-02

“The rear axle of my 2002 Ford Windstar completely fractured while traveling on Interstate 75. The rear axle broke while driving about 60 miles per hour on Interstate 75 in Florida. By the grace of GOD my passenger and I survived. In attempting to stop, the van hit the guard rail”
— Owner report, NHTSA ODI #11449963
“Axle broke on rt side just underneath the bracket that ford installed for recall.i was only going 10mph when it happened no warning I was able to gain control and stop was towed into a shop not driveable if this seems to be a problem mine looked fine they must filled it up with”
— Owner report, NHTSA ODI #11660690
“THEY HAD A RECALL IN 2011 WHERE THEY PUT SUPPORT BRACKETS ON THE REAR AXLES. MINE DID HAVE THE BRACKETS PUT ON AND RIGHT BEHIND THE BRACKET THE AXLE STILL BROKE DRIVING DOWN THE STREET AT 40 MPH WHERE WE ALMOST HIT ANOTHER CAR WITH CHILDREN INSIDE HER AND MY VEHICLE. FORD SAID”
— Owner report, NHTSA ODI #10715920

Read all complaints on NHTSA →

Subframe and engine cradle corrosion causing steering loss

STRUCTURE

17 NHTSA complaints · 2015-05 → 2026-02

“The contact owns a 2002 Ford Windstar. The contact received notifications of NHTSA Campaign Numbers: 11V030000 (STRUCTURE) and 15V608000 (SUSPENSION). The contact stated that while approaching a traffic signal and driving slowly, the vehicle shook, and the engine shifted. The”
— Owner report, NHTSA ODI #11720212
“HUSBAND WAS GOING TO WORK IN EARLY MORNING AND HAD JUST SLOWED AS HE EXITED HIGHWAY, WENT OVER FIRST SET OF RAILROAD TRACKS AT SPEED LIMIT, THEN THE FRONT END OF VAN RAISED INTO THE AIR ABOUT A FOOT THEN SLAMMED DOWN AS HE CROSSED THE SECOND SET OF TRACKS AND HE LOST CONTROL. HE”
— Owner report, NHTSA ODI #10894628
“TL* THE CONTACT OWNS A 2002 FORD WINDSTAR. THE CONTACT STATED THAT WHILE STOPPED, THE CONTACT HEARD AN UNKNOWN PART DETACH FROM THE VEHICLE. THE CONTACT STATED THAT THE STEERING WHEEL THEN BECAME DIFFICULT TO TURN. THE VEHICLE WAS TOWED TO THE RESIDENCE. AN INDEPENDENT MECHANIC”
— Owner report, NHTSA ODI #11322732

Read all complaints on NHTSA →

Instrument cluster gauges erratic with stalling

ELECTRICAL SYSTEM, VEHICLE SPEED CONTROL, ENGINE

7 NHTSA complaints · 2015-04 → 2025-04

“WHILE DRIVING, THE SPEEDOMETER, TACHOMETER, FUEL GAUGE AND TEMPERATURE NEEDLES STARTED "DANCING" (BOUNCING ALL OVER THE PLACE). WHEN I CAME TO A STOP, THE SPEEDOMETER NEEDLE HAD GONE ALL THE WAY TO THE RIGHT AND WAS STUCK THERE, BLOCKING THE GEAR SHIFT INDICATOR AND NOT LETTING”
— Owner report, NHTSA ODI #10884607
“The gauges are acting crazy which causes the engine to jerk or the transmission and then it starts making the lights flicker in the interior and the gauges start sticking. It seems to make the overflow on the radiator to empty more because it is causing the sensors in the”
— Owner report, NHTSA ODI #11495403

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

172 crashes 1990–2024

How the 172 occupant deaths break down

99

driver deaths

73

passenger deaths

172

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2002 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

47

complaints mentioning a crash

52

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Ford Windstar reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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