Investigations
Front Subframe Corrosion Failures
NHTSA Preliminary Evaluation PE10026 — closed, opened 2010-07-20 and involving the FORD WINDSTAR.
NHTSA investigation PE10026 is a Preliminary Evaluation opened on 2010-07-20 and currently closed. The subject of record is FORD WINDSTAR, which places this file inside the Office of Defects Investigation queue for FORD. Latest activity on this investigation was logged on 2010-12-20 — NHTSA updates that field whenever an Information Request goes out, a supplement is filed, or a status change is recorded in the public docket.
A Preliminary Evaluation like PE10026 is the entry point of the federal defect-investigation process. NHTSA engineers scan complaint databases, field reports, and manufacturer data to decide whether an Engineering Analysis is warranted, whether a voluntary recall is already sufficient, or whether the pattern does not rise to a defect finding.
Investigators summarized the matter as follows: "The Office of Defects Investigation (ODI) has identified 346 complaints to ODI and Ford alleging fracture, cracking and or excessive corrosion of the front subframes in model year (MY) 1999 through 2003 Ford Windstar veh..." Investigations are the early-warning layer of the federal auto-safety system, sitting upstream of formal recalls and defect orders. Whether this one closes without action or escalates into an Engineering Analysis, the full history stays in the ODI archive so researchers, litigators, and buyers can pull the paper trail at any time. Related FORD files, listed below, give context on whether this is an isolated concern or part of a broader pattern across the brand.
Investigation Summary
The Office of Defects Investigation (ODI) has identified 346 complaints to ODI and Ford alleging fracture, cracking and or excessive corrosion of the front subframes in model year (MY) 1999 through 2003 Ford Windstar vehicles. Approximately 97 percent of these complaints (334) involve vehicles that have been operated in Salt Belt states, which make up approximately 60 percent of the subject vehicle sales in the United States. The front subframe, sometimes referred to as the engine cradle, is a structural component of the Windstar vehicles that carries the engine, transaxle, steering rack and certain front suspension components (e.g., lower control arm). For complaints with sufficient information to identify the location of the failure, most describe problems with the rear mounting bracket for the front passenger-side lower control arm with some related to the rear body mount attachment located in the same general area of the subframe (right-rear section near the front passenger wheel). The remainder of the reports allege fracture of the front subframe at other or, most often, unspecified locations. Almost all of the complaints that specified the side of the vehicle indicated that the problem occurred on the right/passenger side (106), with only a few indicating the left/driver side (2) or both sides (3) were affected. Ford and several complainants attributed the right-side failures to the routing of the air-conditioning lines above the front subframe on that side of the vehicle, further noting that condensation has been observed dripping onto the front subframe in the area of the affected components (the A/C drain tube is also located on the right side, near the front subframe). ODI has identified 93 complaints related to lower control arm attachments, including 80 that appear to involve complete separations. All but one of these involved vehicles from Salt Belt states. All three crash incidents appear to be related to lower control arm separations, including one ro
About This Investigation Type
A Preliminary Evaluation (PE) is the first phase of NHTSA's investigation process. It is opened when the agency identifies a potential safety defect pattern, usually triggered by consumer complaints, manufacturer reports, or field monitoring. During a PE, NHTSA gathers information to determine whether a formal engineering analysis is warranted.
Other FORD Investigations
Unintended Transmission Downshift and Rear Wheel Lock-up
Timing Belt Failure
Underbody shields detachment
B-Pillar Trim Detachment
Unintended Transmission Downshift and Rear Wheel Lock-up
Data from NHTSA Office of Defects Investigation. Cross-references: NHTSA recall campaign API and NHTSA FARS where fatality records overlap. PlainCars does not rate or recommend vehicles. Learn more.
Read our methodology — how this data is sourced, computed, and verified.