2002 Ford Windstar

The 2002 Ford Windstar was a popular minivan known for its comfortable ride, spacious interior, and family-friendly features. It was available with two engine options: a 3.0L Vulcan V6 producing approximately 150 horsepower and 200 lb-ft of torque, and a 3.8L Essex V6, which was the more common choice, delivering around 200 horsepower and 240 lb-ft of torque. Both engines were paired with a 4-speed automatic transmission. Owners generally appreciated the Windstar’s practicality and cargo capacity, but common complaints centered around reliability issues, particularly with the transmission and some electrical components.

Engine

3.0L Vulcan V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leaks, rough idle, overheating, and potential engine damage.
  • Solution: Replacing the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+

3.8L Essex V6

• Head Gasket Failure
  • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, and potential engine damage.
  • Solution: Replacing the head gaskets and potentially machining the cylinder heads.
  • Estimated Cost to Fix: $1200 - $2500+
• Fuel Injector Failure
  • Description/Symptoms: Rough idle, misfires, poor fuel economy.
  • Solution: Replacing the faulty fuel injector(s).
  • Estimated Cost to Fix: $150 - $300+ per injector (depending on location and accessibility)

Transmission

4-Speed Automatic (4F50N)

• Transmission Slipping/Harsh Shifting
  • Description/Symptoms: Delayed engagement, slipping between gears, harsh upshifts and downshifts, or complete transmission failure.
  • Solution: This could require a transmission rebuild or replacement. Internal damage may include worn clutches, damaged valve body, or torque converter issues.
  • Estimated Cost to Fix: $1800 - $3500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering, stalling, poor acceleration, transmission overheating.
  • Solution: Replacing the torque converter.
  • Estimated Cost to Fix: $500 - $1200+

Suspension

• Rear Leaf Spring Sagging/Breaking
  • Description/Symptoms: Rear of the vehicle sitting lower than normal, reduced ride quality, potential for spring breakage.
  • Solution: Replacing the rear leaf springs.
  • Estimated Cost to Fix: $400 - $800+
• Front Strut/Coil Spring Failure
  • Description/Symptoms: Bouncy ride, clunking noises, uneven tire wear.
  • Solution: Replacing the front struts and potentially the coil springs.
  • Estimated Cost to Fix: $300 - $700+ per side

Electrical

• Power Door Lock Actuator Failure
  • Description/Symptoms: Power door locks failing to function properly (intermittently or completely).
  • Solution: Replacing the faulty door lock actuator.
  • Estimated Cost to Fix: $150 - $300+ per door
• Window Motor Failure
  • Description/Symptoms: Window not operating or operating slowly/erratically.
  • Solution: Replacing the window motor.
  • Estimated Cost to Fix: $200 - $400+ per window
• Instrument Cluster Issues
  • Description/Symptoms: Gauges not working, intermittent flickering, or complete failure of the instrument cluster.
  • Solution: Replacing or repairing the instrument cluster.
  • Estimated Cost to Fix: $200 - $600+

Exterior

• Rust on Rocker Panels and Wheel Wells
  • Description/Symptoms: Visible rust on the lower body panels, particularly around the wheel wells and rocker panels.
  • Solution: Rust repair and panel replacement.
  • Estimated Cost to Fix: $500 - $2000+ (depending on severity)

Interior

• Power Sliding Door Problems
  • Description/Symptoms: Power sliding doors failing to open/close reliably or at all.
  • Solution: Diagnosing and repairing or replacing the power sliding door motor, track, or associated sensors/modules.
  • Estimated Cost to Fix: $300 - $800+ per door
• Air Conditioning Issues
  • Description/Symptoms: Weak or no cold air, malfunctioning blend door actuator (temperature control issues).
  • Solution: Repairing refrigerant leaks, replacing the compressor, or replacing the blend door actuator.
  • Estimated Cost to Fix: $200 - $1000+

Summary

The 2002 Ford Windstar, while spacious and practical, is prone to a number of reliability issues. Engine problems like head gasket failures (3.8L) and intake manifold leaks (3.0L) can be costly to repair. The 4-speed automatic transmission is a known weak point, with slipping and harsh shifting being common complaints. Electrical issues such as power door lock and window motor failures are also frequent. Suspension problems like sagging leaf springs affect ride quality. While some repairs are relatively inexpensive, others, like transmission rebuilds or extensive rust repair, can be significant expenses. Potential buyers should be aware of these common issues and factor in potential repair costs.