Ford Windstar

Year-by-year changes

1998 Ford Windstar

• 1995: Introduced in March 1994, the Windstar is available as GL, LX, and cargo van models. 3.8L V6 is only engine available.
• 1996: Introduced in October 1995, a new 3.0 L 150 hp (112 kW) Vulcan V6 became standard on base GL models, while the larger 3.8 L V6's horsepower was increased to 200. Also added was the all-speed traction control on GL and LX models. Quad command seating was now made available on the higher line GL models as well. In efforts to cut costs, the LX seat trim was changed as well.
• 1997: A bare-bones unnamed base model called the 3.0l was now available. A CD player was an option. Short model year ran from October 1996 to January 1997, due to the updated model.
• 1998: In January 1997, the Windstar underwent light cosmetic changes. The front featured a new grille, hood and headlights for a more streamlined appearance. In the rear, the blue-oval Ford logo on the rear liftgate was now centered above the license plate; previously, it was located in the lower right corner. The bodyside moldings were also revised and the rear power vent window switches were moved to the drivers door. A Limited model was new. It included leather seating and faux wood interior trim body colored mirrors and chrome wheels. Second-generation airbags that deployed with less force were also new for 1998. Headrests were added to middle and third-row bench seats. The driver's seat gained an available tilt/slide feature for access to the rear from the driver's side with a 6 inch longer drivers door. A "Northwoods" edition was also available on GL and LX Models which featured Leather Seating (LX) and Unique Cloth Seats with Vinyl Trim (GL), Gold Painted wheels (LX) and Gold Wheel Pockets (GL), gold painted luggage rack and a unique two-tone color combination. The cargo area door lock button was also deleted.

To compensate for the lack of a driver's side sliding door, the edge of the driver's door was extended rearward six inches (152 mm); it was not possible to create a driver's side sliding door with the current body shell as the entire safety structure of the Windstar was designed as it being a 3 door vehicle. When the Windstar was being designed in the early 1990s, Ford claimed that a driver's side sliding door was not noted as a key feature indicated by focus groups; also at that time, minivans with that feature had sold very poorly.

Trim levels

In a break from the Aerostar and Econoline tradition of using the traditional Ford truck XL/XLT trim nomenclature, the Windstar adopted the model hierarchy seen in the majority of the Ford car lineup. For retail sales, base trim Wagons were GL models while high-end models were given LX badging.

• Cargo Van (1995–1998)
• base (1996–1998)
• GL (1995–1998)
• LX (1995–1998)
• 3.0L (1998)
• Limited (1998)

Problems

1998 United States Postal Service Ford Windstar, showing the larger driver's side door

During and after its production, this generation of the Windstar would become known for several notable reliability issues. The 3.8 L V6 Essex engine in 1995 models was susceptible to headgasket failure, as it was its Taurus and Sable stablemates. However, the Windstar's problem was exacerbated by a tighter engine bay and higher loads, the van being 700 pounds heavier. In response, Ford extended the warranty on the headgasket to 100,000 miles on most Windstars with this engine. The 3.0 L V6 Vulcan engine was not susceptible to headgasket failure, as it was a completely different engine design.

The Windstar was paired with an AX4S transaxle, which was prone to internal failure. The transmission suffered from cracked forward and reverse clutch pistons. These transmission failures were most susceptible with the 3.8L engine, as the transmission could not handle the extra torque and the extra vehicle weight.

The Windstar was also plagued with various suspension woes. The front springs were prone to breaking in specific markets where extreme cold and heavy salt use in winter months occurred.

IIHS crash test results

The 1995–1998 Ford Windstar, which was tested as a 1995 model received a "Good" (5-stars)^[8] rating from the IIHS in all marks, in which the driver survives the accident without any injuries.

Year-by-year changes

• 2000: The Limited model returned as the most luxurious model. A VCR-based rear-seat entertainment system featuring a flip-down LCD screen was a new option on SE, SEL, and Limited models.
• 2001: Slight cosmetic changes were made to front and rear fascias for '01. LX became the base model, and a new SE Sport model joined the lineup. The smaller 3.0 L was gone, leaving the 3.8 L as the sole engine choice. Models with 2nd row bucket seats now got their own center console. Front-seat side airbags became standard on Limiteds. The chrome grille on the SE and SEL models was redesigned. The steering wheel was updated to a more modern style, with the blue Ford Logo placed in the center. The transmission was updated to the 4F50N.
• 2002: Dual sliding doors became standard on all models.

The 2002 Windstar was the most dependable minivan on the market in the JD Powers dependability survey at three years in service in the 2005 survey. The Windstar beat out the Toyota Sienna and the Honda Odyssey for these honors.^[9]

• 2003: The last year of the Windstar; no major changes were made in anticipation of a 2004 redesign. In a new marketing strategy, the upcoming third-generation Windstar was rebranded as the Ford Freestar. The last Ford Windstar was produced on July 25, 2003.

Trim levels

2001–2003 Ford Windstar SE Sport

In 1999, Ford began a shift in trim levels that would be seen in many of its American-market sedans through the 2000s. In place of the GL, the LX was the new base model, with the SE and SEL making their debut as the highest trim levels, respectively.

Although all versions of the Windstar wagon were sold with 7-passenger seating, LX-trim Windstars are equipped with 2nd-row bench seats; SE and SEL-trim examples are equipped with 2nd-row bucket seats.

• Cargo Van (1999–2003)
• base (1999–2000)
• LX (1999–2003)
• SE (1999–2003)
• SE Sport (2001–2003)
• SEL (1999–2003)
• Limited (2000–2003)

Recalls

Rear Axle:

In August 2010, Ford issued a voluntary recall of 575,000 Windstar minivans for rear axle problems. This recall followed an investigation by the National Highway Traffic Safety Administration which had begun in May 2010. The NHTSA preliminary evaluation stated the design of the rear axle beam, an inverted "U" channel design, appeared to provide a collection point for road slurry. In states which used lots of road salt, corrosion progressively weakened the axle until it fractured.^[10] The states covered by the recall were Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Utah, Vermont, West Virginia and Wisconsin, as well as Washington D.C.^[11] In May 2012, 27,000 of the minivans from Virginia were added to the axle recall, bringing the overall total to more than 600,000 vehicles between the U.S. and Canada.^[12]

A class action lawsuit was filed against Ford Motor Company in May 2010 proceeding Ford's recall.^[13] This lawsuit was filed by Plaintiff Aaron Martin against Defendant Ford Motor Company. In this lawsuit, documents were introduced which showed Ford's testing of the Benteler Axle in March 1998 resulted in failure of two out of the eleven axles tested. In August 1998, Ford determined the cause of this failure was improper heat treating. In September 1998, the axle manufacturer Bentley Automotive agreed with Ford's findings. In October 1999, Ford's internal documents show lab testing proved the axle life could be doubled by heat treating, but would require initial retooling cost and result in $3.45 piece cost increase. No changes were made until March 2003.^[13]

Subframe Corrosion:

In March 2011 the National Highway Traffic Safety Administration and Ford announced another Ford Windstar recall over corrosion concerns. 425,288 of the model year 1999–2003 Windstar vans originally sold or currently registered in some cold weather states are part of the recall. The problem involves rusting of the subframe. Most of the corrosion occurs on the passenger side of the subframe. If the subframe collapses while driving, the vehicle could potentially lose all steering control and end up in an accident. According to the NHTSA action #PE10026, some Ford Windstar owners had their drive axle detach from the transmission. Ford is offering alternative transportation to owners if their vehicle is unsafe to drive. If the minivan can't be repaired, Ford will repurchase the vehicle.^[14]

IIHS crash test results

The 1999–2003 Ford Windstar received an "Acceptable" rating by the IIHS for fair structural performance, moderate injuries to the left foot, and fair dummy control. Although most redesigned vehicles outperform their predecessors to cut down insurance costs and possible injuries to the driver, this generation Windstar did not perform as well as its first generation predecessor. The NHTSA graded the minivan an overall rating of 5 stars in both the frontal and side impact tests.

Yearly American sales

Trim levels

The Freestar carried much of the trim lineup from the Windstar, with two exceptions. While the LX trim was dropped, the Sport trim became a separate trim from the SE.

• base (2004–2007)
• SE (2004–2007)
• Sport (2004–2007)
• SEL (2004–2007)
• Limited (2004–2007)

IIHS crash test results

The 2004–2007 Ford Freestar received a "Good" rating in the offset frontal crash test from the IIHS and outperformed the 1999–2003 Ford Windstar, but resulted in moderate injuries only on the head and neck. In the side-impact tests, it received a "Poor" rating without the optional side airbags for poor structural performance, potential head and neck injuries, and high forces on the driver's torso, but fared better with the side airbags, earning an overall "Acceptable" rating, but resulted in a moderate head and neck injury to the driver.

Yearly American sales

Awards

In 2009, the 2005 Freestar scored second place in J.D. Power's Vehicle Dependability Study, behind the Dodge Caravan.^[21]

Mercury Monterey

For the 1950–1974 full-size car, see Mercury Monterey.

Mercury Monterey

For the 2004 model year, the Lincoln-Mercury division marketed a Ford-developed minivan for the first time. Replacing the discontinued Mercury Villager, the Mercury division revived the Mercury Monterey name (for the first time since 1974) to give the division its first competitor for the Chrysler Town & Country and the newly introduced Buick Terraza (replacing the Oldsmobile Silhouette). In Mercury tradition, the Monterey was priced slightly higher than the Ford Freestar, differentiated primarily by trim options; its sole engine was the 4.2L V6.

The Monterey was introduced in three trim levels: Convenience, Luxury, and Premier. Features such as power-sliding doors and a rear-seat DVD player were available on Luxury and Premier trim lines. Unique to the Premier was the option of heated and cooled front seats, a class exclusive at the time.

However, sales of the Monterey were very low as the design proved uncompetitive against stronger entries from other automakers, as well as an overall decline in the minivan market. Final sale numbers after a three-year run totaled 32,195.