1991 Ford Windstar problems

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The Ford Windstar (later the Ford Freestar and Mercury Monterey) is a minivan that was produced and sold by Ford. The replacement for the Ford Aerostar, the Windstar adopted the front-wheel drive configuration of the Chrysler minivans. From the 1995 to 2007 model years, three generations of the model line were sold, with the final generation renamed as the Ford Freestar.

Unrelated to the Nissan-developed Mercury Villager, the Windstar was marketed without a Lincoln-Mercury counterpart. As part of the 2004 launch of the Ford Freestar, Mercury introduced its first Ford-produced minivan in a revival of the Mercury Monterey nameplate.

Following a decline in sales across the minivan segment in the mid-2000s, the Freestar and Monterey were discontinued after the 2007 model year with no direct replacement. In North America, the model line was functionally matched by the 7-passenger 2008 Ford Taurus X wagon/CUV; in Mexico, the Freestar was replaced by the Ford Transit/Tourneo. In 2014, Ford reentered the segment as the Ford Transit Connect compact MPV gained 7-passenger seating in North America.

During its production the Ford Windstar/Freestar and the Mercury Monterey were sourced from Oakville Assembly (Oakville, Ontario). In total, 1,984,232 were produced (1,704,786 Windstars, 246,493 Freestars, and 32,953 Montereys).

1991 Ford Windstar

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Common 1991 Ford Windstar problems

The Ford Windstar, produced from 1991 to 2003, has been known to have several common problems that have been reported by owners. These issues span various components of the vehicle, including the electrical system, rear axle, and transmission.

Electrical Problems:

One of the most common problems reported by Ford Windstar owners is related to the electrical system. These issues include windows that won't go down, interior lights that don't function properly, and door ajar warnings that remain on even when the door is closed. Some owners have reported that these problems are related to temperature, suggesting that they may be more prevalent in colder regions. In some cases, these electrical issues have led to frustration and the desire for a class-action lawsuit against Ford.

Rear Axle Problems:

Another issue that has affected Ford Windstar owners is related to the rear axle. Over 200 owners of Windstars manufactured between 1999 and 2003 have reported sudden failure of their rear axles to the National Highway Traffic Safety Administration (NHTSA). These failures have resulted in a loss of control, swerving, and stalling, putting occupants at risk of being hit by other vehicles. Despite these reports, the NHTSA has not initiated a safety investigation. Ford has acknowledged the issue but downplayed its severity, stating that most failures occurred after the factory warranty and that the operator retains control of the vehicle. However, some safety experts have expressed concern, considering the rear axle breaking to be a dangerous event.

Transmission Problems:

Transmission problems have also been reported by Ford Windstar owners. These issues include sudden lethargy, lunging forward or backward, and refusal to shift. These problems tend to occur around the 98,000-mile mark and can cost up to $3000 to repair. In some cases, the average repair cost is as high as $7000.

Other Issues:

In addition to these problems, the Ford Windstar has also been known to have issues with the power steering system, PCM, electrical problems, and wheel-bearing problems. These issues can result in costly repairs and inconvenience for owners.

In summary, the Ford Windstar has been known to have several common problems, including electrical issues, rear axle failures, and transmission problems. These issues can result in costly repairs and safety concerns for owners. It is important for Ford Windstar owners to be aware of these potential issues and to seek professional assistance if they experience any problems with their vehicle.

1991 Ford Windstar engine

How many miles do Ford Windstars last?

How Long Will the 2003 Ford Windstar Last? Drivers are typically reporting mileage in the low 200,000 range before the transmission totally goes out, but we're also seeing reports as low as 100,000 before something needs to be rebuilt or swapped out. Expect a fairly meager typical lifespan of 180,000 miles.

How good are Ford Windstar vans?

The average rating is a 3.5 out of 5 stars.

Why did Ford stop making the Windstar?

Transmission issues plagued early models, and concerns about reliability dogged the minivan throughout its production run. Additionally, some criticized its handling, particularly in comparison to its nimbler competitors. In 2007, Ford discontinued the Windstar, replaced by the larger and more truck-like Freestar.

What kind of engine does a Ford Windstar have?

It was slotted above the Ford Galaxy in size and equipment level. The sole powertrain was the 3.0 L V6 engine and automatic transmission, with no diesel engine nor manual transmission available.

How good are Ford Windstar vans?

The average rating is a 3.5 out of 5 stars.

How long do Ford Windstars last?

Expect a fairly meager typical lifespan of 180,000 miles.

Why did Ford stop making the Windstar?

Transmission issues plagued early models, and concerns about reliability dogged the minivan throughout its production run. Additionally, some criticized its handling, particularly in comparison to its nimbler competitors. In 2007, Ford discontinued the Windstar, replaced by the larger and more truck-like Freestar.

What engine is in a Ford Windstar?

3.8L V6

Powertrain. The Windstar shared its powertrains with the Ford Taurus/Mercury Sable. For its 1995 launch, the 3.8L V6 was the sole engine in GL and LX Models, producing 155 hp; a 150 hp 3.0L V6 was introduced as the standard engine in October 1995 for base and lower GL models.

1991 Ford Windstar car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Ford Windstar problems, we found that the most common problems with these 2023 model year vehicles are:

  • Structure problems
  • Vehicle speed control problems
  • Visibility problems

The graph below shows statistics for all 1991 Ford Windstar vehicle components and the number of complaints received.

1991 Ford Windstar complaints

The NHTSA has received 3 complaints about various vehicle components related to the 1991 Ford Windstar.

2011-05-30

STRUCTURE PROBLEM

  • Date Of Incident: 2011-05-27
  • VIN: 2FMDA5244XB
  • Components: STRUCTURE
  • Summary: 1991 FORD WINDSTAR SUBFRAME BEHIND PASSENGER SIDE FRONT TIRE HAS SPLIT. SIGNS OF RUST IN THE AREA OF THE SPLIT. *TR
2009-12-07

VEHICLE SPEED CONTROL PROBLEM

  • Date Of Incident: 2009-11-24
  • Components: VEHICLE SPEED CONTROL
  • Summary: TL* THE CONTACT OWNS A 1991 FORD WINDSTAR. HE RECEIVED A RECALL NOTIFICATION REGARDING THE VEHICLE SPEED CONTROL. HE NOTIFIED SIX DIFFERENT AUTHORIZED DEALERS TO SCHEDULE AN APPOINTMENT FOR THE RECALL REMEDY REPAIR. HOWEVER, THE DEALER REFUSED TO SCHEDULE RECALL REPAIR APPOINTMENTS WITHIN A REASONABLE TIME FRAME. EVENTUALLY HE WAS ABLE TO LOCATE A DEALER THAT WAS WILLING TO REPAIR THE VEHICLE WITHIN A REASONABLE PERIOD OF TIME. THE CURRENT MILEAGE WAS 65,000. THE VEHICLE IDENTIFICATION NUMBER WAS UNAVAILABLE.
2002-03-25

VISIBILITY PROBLEM

  • Date Of Incident: 2024-11-24
  • Components: VISIBILITY
  • Summary: LEFT SIDE/DRIVERS SIDE MIRROR HAS A BLIND SPOT. DEALERSHIP IS AWARE OF PROBLEM. *AK CONSUMER ADDS THAT WHEN A VEHICLE IS ABOUT TO CHANGE LANES AND ANOTHER VEHICLE IS ALONG SIDE IN THE LEFT LANE, THE MIRROR WILL NOT SHOW THE ONCOMING VEHICLE. *TT CONSUMER INSTALLED A BLIND SPOT CONVEX MIRROR TO HELP ILLEVIATE THE BLIND SPOT. *SLC
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Additional sources

More sources of information about 1991 Ford Windstar problems:

Ford Windstar 3.8: Troubleshooting Common Problems | JustAnswer
Ford Windstar 3.8: Troubleshooting Common Problems | JustAnswer
https://www.justanswer.com/ford/9plfp-2003-ford-windstar-3-8-no-start-cranks-runs.html

May 19, 2016 ... 2003 ford windstar...3.8---no start.. cranks and runs for a second then dies. replaced fuel pump and filter. what should - Answered by a ...

Why did the Ford Windstar/Freestar flop so hard compared to the ...
Why did the Ford Windstar/Freestar flop so hard compared to the ...
https://www.reddit.com/r/regularcarreviews/comments/17unf48/why_did_the_ford_windstarfreestar_flop_so_hard/

Nov 13, 2023 ... My dad had a '91 ... Ford Windstar with the original engine and transmission ... issues with the 3.8 like cracking heads and head gasket failure as ...

2000 ford windstar: fouling out spark plugs..there any common issues
2000 ford windstar: fouling out spark plugs..there any common issues
https://www.justanswer.com/ford/6k7ea-ford-2000-ford-windstar-3-8-constantly-fouling-spark-plugs.html

Apr 21, 2012 ... 2000 ford windstar 3.8 constantly fouling out spark plugs. seems like every month the plugs are once again fouled.

2002 Ford Windstar - code scan p1518
2002 Ford Windstar - code scan p1518
https://repairpal.com/code-scan-p1518-707

Apr 4, 2009 ... They get brittle from the engine heat, break or otherwise fall apart, and the rod falls out, a common problem with this engine. Sign in to reply.

2000 Windstar Charging System Problems - Ford Forum - Enthusiast ...
2000 Windstar Charging System Problems - Ford Forum - Enthusiast ...
https://www.fordforum.com/forum/general-tech-11/2000-windstar-charging-system-problems-8821/

Jul 4, 2007 ... General Tech - 2000 Windstar Charging System Problems - I own a 2000 Ford Windstar SEL. The batterykeeps dying.A charging system check was ...

Other years of Ford Windstar

ford windstar 1992 photo
Windstar 1992
Ford

2

0

0

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  • 4
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ford windstar 1993 photo
Windstar 1993
Ford

11

0

0

  • 5
  • 4
  • 3
  • 2
  • 1
ford windstar 1994 photo
Windstar 1994
Ford

23

0

0

  • 5
  • 4
  • 3
  • 2
  • 1
ford windstar 1995 photo
Windstar 1995
Ford

3777

8

20

  • 5
  • 4
  • 3
  • 2
  • 1
ford windstar 1996 photo
Windstar 1996
Ford

1484

9

26

  • 5
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  • 3
  • 2
  • 1
ford windstar 1997 photo
Windstar 1997
Ford

220

6

27

  • 5
  • 4
  • 3
  • 2
  • 1

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1991 Ford Windstar photo