California version of the Windstar; catalytic converter not operating correctly, causing back pressure to the engine, caused engine input air control valve to become overloaded with carbon deposits which in turn also failed. For 3 months catalytic converter replacement parts have not been available $1400 estimated repair bill for catalytic converters.

- Abingdon, MD, USA

Upper and lower intake manifold gaskets replaced twice, first at 30K then at 50K

- Yardley, PA, USA

: the contact stated the vehicle's check engine light illuminated. The contact took the vehicle to an independent repair shop for inspection. The independent mechanic determined the left valve covers and upper intake gaskets were wrong for this type of vehicle and needed to be replaced.

- New Bedford, MA, USA

Ford Windstar 1996 intake manifold gaskets replaced. Due to the mis-design of the intake manifold failed prematurely. The intake manifold was plastic.

- Hoffman Estates, IL, USA

Vehicle experienced a problem with the valve cover. It was leaking and causing the intake manifold O-rings to fail. The immediate result caused the engine to run very lean. Too much air caused the spark in the engine to be too hot.

- Shrewsbury, MA, USA

The check engine went on and the codes P0171 and P0174 were found. There was an extreme loss in gas mileage leading up to this situation, down to ~10mpg. The gasket manifold, the line leading to it, and the cover assembly for a rocker arm were all replaced at a cost of $543.10. This on a 4yr old vehicle with only 47,000 miles. The dealer acknowledged that they had seen this before in the Windstar. Kind of got the idea it was a chronic problem that should be covered by Ford! in the course of repairing this they also determined that the left front axle seal was leaking and the servo cover gasket was leaking also. These were estimated to cost $465 so I will be spending over $1000 on this vehicle for defects in less than 5 years and under 50,000 miles. What a pile of junk! it will be a long time before I go back to Ford if ever.

- Brown Deer, WI, USA

Check engine light came on..took to Ford service dealer...told me seal to intake manifold was leaking. They do them all the time!! problem is it only requires a few inexpensive seals to repair. Ford will only sell the complete intake manifold with seals. The intake manifold costs @ $600 so the cost of replacing a few faulty seals is 800-$1000. Why does Ford not recall these seals or at least come out with a seal repair kit, so the consumer does not have to throw away a good intake manifold. I have owned this van since new, and I see that I am not the only one that has filed a complaint on this same item. If Ford will not attempt to rectify this small problem, I will definitely be shopping elsewhere.

- Anchorage, AK, USA

Consumer stated that emission light came on. She took the vehicle to the mechanic to be checked. After checking the vehicle, she was told that the intake manifold was leaking. Also, mechanic stated that vehicle was too new to have this problem.

- Max Meadows, VA, USA

Manifold gaskets failed, exhaust sensors failed, fuel injector wires rubbed together causing arc and fuel injector failure, spark plug replaced, spark plug wiring harness failed. Van has approx. 48,000 miles. Also having problems with electrical; power doors, power locks, front-driver power seat, back-up sensors all have failed at one point or another. Van has been serviced for all problems on at least four separate occasions over the period of ownership. We purchased new.

- Broken Arrow, OK, USA

2000 Ford Windstar van check engine light coming on and rough idling, took van to Ford and the problem was intake manifold gasket $850 repair van had 40000.0 miles, what was funny is my boss has the same van and same thing happened to him at 43000.0 miles. I think this is happening more than 4 occurences as stated.

- Friendswood, TX, USA

I bought this vehicle in Nov 2003 from pacific coast Ford in federal way wa. It is now March 2004, I have in the past 4 months had to replace the battery, which would not hold a charge. The tires replaced due to the front pasenger side tire blowing out while driving on the freeway. Next thing was the brakes front and back. The van started all of a sudden making a terrible grinding noise. When I took it in to have it looked at they said it needs brakes. Next I had to have my back windshield replaced due to it shattering with no explanation. The van had not been driven since Friday. Sunday morning my neighbors came to my door to tell me that they were standing outside smoking when all of a sudden my back window had shattered. Following that I had to have the head gasket replaced along with the spark plugs. Which is a manufacture defect on Ford's end. When I took my van into the dealer they told me what was the problem also gave me a bulletin update on the problem. The original exhaust manifold gasket has a small hole in it, then new exhaust manifold does not have this hole. If you ask me Ford should be fixing that! since I have bought this van and had all this trouble I have been online looking up everybody else's comments on this van and all are the same. Faulty head gaskets, brakes, wiring, doors, battery, glass not being installed properly, tires bulging causing blowouts. It seems to me that Ford should own up to these problems. Before this I had financed a brand new 2000 Ford escort drove it down to California from Washington when there was a sudden death in the family and never had not 1 problem with it. The only reason I upgraded to a van is because I have 3 kids and sometimes I have a friend of theirs or something so really we need the room of a van, but with all of this trouble I am thinking about going back to a car! can anyone help me nail Ford on these issues? I am compiling a file and mailing it to headquarters.

- Covington , WA, USA

While traveling on the highway carbon fuel intake into manifold clogged up, causing fumes and bad smoke.

- Des Moines, IA, USA

On 12-13-02 I was told by mile one where I purchased my warranty to have my van towed to a Ford dealship because it had a mechanical breakdown.the service manager john locket said that the van had what he called an intermix in the engine, he said that coolant and the oil had somehow mixed together.I asked him what caused that to happened and he said that it could be a blown headgasket or a cracked cylinderhead. I called him on 12-23-02 and he said told me that the mechanic said that he couldn't tell what the problem was so I would have to give my permission for them to break down the engine at my own expenses and I was told the samething by mile one, I agreed.I contacted the service manager sam steward of Kia of glen burnie where I purchased the van and he agreed to call and speak to the service manager john locket at the Ford dealership.he told him that he would have everything worked out after christmas. Mr. Steward told me to keep in touch and to let him know if I needed anymore assistance.I contacted him again the first part of January and I told him that they still couldn't find the problem so I made a conference call to Mr. Locket with Mr. Steward's permission. Mr. Locket explained to Mr. Steward and myself that I would have to give my permission to have the engine pulled out to have the blocked checked to see if it is cracked I agreed again. Mr. Steward asked Mr. Locket why was it taking so long to find the problem and he said that he was short on help.I spent over 1200 dollars on a rental van and had to catch rides with friends to and from the babysitters and work.I am stress out and I feel like mile one do not want to honor the warranty.I was told today by the Ford dealership service manager john locket that I had to pay a 1000 dollar deductible and they would pay the rest to replace the engine. The engine is covered under the warranty so why do I have to pay a 1000 dollar deductable.

- Capitolheights, MD, USA