Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
FUEL SYSTEM, GASOLINE
98-472109/01/1998607131Premature low fuel warning, slow fuel fill action. *ak11/02/2000
97601111/01/1997605804Experiencing difficulty diagnosing vehicles with evaporative fuel system diagnostic trouble codes. *tt07/26/1999
98030604/01/1998602159Some vehicles experience a premature low fuel warning, slow fuel fill. *yc09/23/1998
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
981801/19/1998605568Fuel pump replacement procedure - service tip. *tt07/09/1999
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
98-474309/01/1998607160Fuel tank problems. *ak11/03/2000
98-031601/01/1998607717Concerns with slow fuel fill, distorted fuel tank, fuel gage erratic, fuel odor. *tt10/07/1999
BC10590970505/01/199752870Instructions on how to identify fuel tank sizes. *tw09/18/1997
FUEL SYSTEM, OTHER
039805/12/200310002780Malfunction indicator lamp (mil) illumination with diagnostic trouble codes p0442, p0455, p0456, p0457, p1442 or check fuel cap lamp illuminated with diagnostic trouble code p0457. *tt09/17/2003
98505611/01/1998613192Repeat message regarding premature low fuel warning, slow fuel fill. *tt06/19/2000
9915407/26/1999608433Concerns with the low fuel lamp illuminating too early occurring with a 19-26 l (5-7 gallon) fuel reserve on vehicles equipped with a 95 l (25 gallon) fuel tanik. *tt12/01/1999
98317102/17/1998607420Conditions with the fuel gau-ge not reading full or the gauge may prematurely drop to the 3/4 mark. *tt09/22/1999
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
461808/01/1998615156Brief information vehicles exhibiting premature low fuel warning, slow fuel fill. *tt01/02/2001

Consumer Complaints


Fail datemilesoccurencesPurchase date
FUEL SYSTEM, GASOLINE
01/03/20111
 1998 ford windstar. consumer states issues with repairs *tgw the consumer stated the gas he put in his vehicle, turned out to be bad, which caused the vehicle shake. (consumers handwriting is extremely illegible. ) *jb
12/15/199950930
 A/c oct. 99 $168.98, dec. 99 $134.40 suspension july 01 $664.61, dec. 99 $515.85, jun 01 $61.78, body jun 01 $443.61 other cd player jun 01 $19.50 and $366.86 turn signal jan 02 $161.04 dome light jan 02 $84.02 jan 02 $89.72 door oct 99 $134.52, mar 03 $285.07 steering sept.02 $258.82, mar. 03 569.32 computer controls sept. 00 $106.02 engine jan 02 $784.75 coolant smell (found front cover gasket leaking) sept. 02 85.95 (told throttle body worn out, sold me update computer software, seams to run better) currently in shop for check engine light and a/c system intermittent. mechanic found engine problem, says main bearings or crankshaft bad, possibly due to coolant in oil system from january 02 problem
05/15/200137000
 This van has all the defects and complaints listed on thegovt. recalls the nhtsa site and others ihave too much info to put on this site if there is anyone i can send my complaint to please let me know iam putting it back into the shop again ive been thru a nightmare along with trying to assure my 4 kids that they were safe in this van thankyou angela wallace and by the wat the dealer that sold me this van will not cooperate at all
11/15/200284000
 Head gasket failure. faulty head gasket design in my opinion abs/traction control unit. current problem tsb states that fuel tank manufactured with incorrect depth - fuel pump wiring is rubbed until electrical short occurs - and fuel pump fuse blows - vehicle is then stuck in traffic, in the middle of an intersection etc. fords recommended fix is to replace the fuel tank and pump assembly however, they will not contribute anything to the cost of the repairs caused due to their faulty design.
09/26/2003950001
 While driving at various speeds and without warning consumer smelled gas fumes inside the vehicle. cause has yet to be determined. *ak the seal between the gas tank and the fuel pump failed because the gas tank collapsed. the gas tank was replaced at the dealer. the fuel gauge accuracy problem that was corrected when the new gas tank was installed. *scc
07/01/20021
 Consumer states the warning light was on, the dealer traced problem to a loose hose on the fuel tank, which required tightening a screw, the fuel filter was replaced.*jb
07/20/20022003/01/2098
 Engine stalled; reported to sheehy ford; replaced sensor; within a week vehicle stalled again and often. reported to dealer; could not duplicate stall condition. stalling occurred up to 13 times a day; returned vehicle to dealer. after two days dealer found that plastic gas tank had collapsed, causing a vapor lock, affecting fuel flow to engine and resulting in stalls. gas tank replaced at cost of $882.*ak
FUEL SYSTEM, GASOLINE - CARBURETOR SYSTEM
05/28/2002107/01/1997
 White smoke coming from the exhaust and the engine was missing due to blown head gaskets. dealer contacted. *ak also found blown intake manifold gasket. transmission replaced at 45,000 miles. *tt
FUEL SYSTEM, GASOLINE - DELIVERY
06/24/2001102/01/1999
 Problem area: wiring in gas tank-- the hose clamp inside gas tank has rubbed through the wires which power the electric pump. this caused to blow the fuse for the gas pump. *note-possible electric arc inside the gas tank.
1309/01/2000
 After each fill up car stalls after one block while driving, but the car restarts. interior and headlites at times will not go on, delays about 10 mins then goes on this is intermit. problem. rear windows also intermit. opens after a few times when button is depressed. used car dealer will check on nov. 2nd. is this a problem with ford?
02/24/2000107/01/1998
 No summary listed for abov evehicle. *ak
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
06/26/200580900109/01/2003
 Dt: contact stated the fuel sending unit and the fuel pump harness melted. dealer told contact she was lucky the vehicle did not blow up on her. this happened while she was driving the vehicle. the check engine light came on, and then vehicle coasted to a stop.*ak
04/22/2004960003608/23/1998
 Surging, lack of power, stalling, no start condition
10/01/200350000102/20/2000
 I have a 1998 ford windstar, and its fuel tank was leaking into the passenger compartment. when brought to the dealer it was said that the fuel tank collapsed at the fuel pump, which caused the leaking. *la
08/15/2002
 Fuel pump has stopped working due to insulation on wires wore off, which in some cases could result in a fire. contacted dealer. *ak
07/31/20022012/15/1999
 There are wires going through fuel tank that have no cover, and it could cause a fire. dealer notified. *ak the vehicle had stalled several times due to wires shorting out in the fuel pump. the fuel pump was replaced. yh
06/30/2002102/01/1998
 Fuel pump inside fuel tank is not working properly. there is a wire inside fuel tank connected to fuel pump, and within 50000 miles wire started to rub together with potential of there being a fire in fuel tank. contacted dealer, and the dealer was not willing to do anything.*ak
06/22/2001105/01/1999
 I had a fuse blow on my fuel pump.this pump is in the tank and the tank was full.when the mechanic removed the tank he found two wires with thethe coatings burnt off.a pieceof one wire was welded to one of the tubes.this could have caused a fire or if the tank wasnot full more likely an explosion.it is fused with 25amp.i believe this to be avery dangerous condition .ihave the pump also pictures of same.please keep me advised of your findings.if you need more info just call or e-mail.*ak
06/01/2000312/01/1997
 Fuel pump fuse blew which could have caused a fire. *slc
02/01/200001/01/1998
 1st to 2nd bang when shifting on slow acceleration (repeats often), fuel pump continually cuts out when parked on slight downhill, still 6+ gallons left. only since replacement of fueltank and gas pump due to electrical short
03/01/1998
 Ie99059, the defective steering bushings does not support the system which causes the vehicle steering system to malfuction. also, braking system malfunctioned, causing extended stopping distance which may result in a crash. the fuel pump went out unexpectedly, cause vehicle to stall. finally, liftgate indicator light came on, but the liftgate remained closed. brakes been replace once,and bushings 3 times. please provide further information and vin#. *ak
07/20/1999
 For no apparent reason the vehicle just cuts off while driving. the first time a computer adjustment was made, the second time(july 23rd) the electric fuel pump was replaced. the vehicle is being service for the third time(aug 5th) for the same problem. each time the vehicle had to be towed to the dealership. *ak
12/01/1997104/01/1997
 Fuel pump failed.
08/09/1998102/13/1998
 While driving 30 mph down hill the fuel pump will shutdown, which was caused by a short in the sensor of the fuel tank. dealer replaced the fuel pump and the tank. *ak consumer states that the tank was a 25 gallon tank, however the sensor was causing the low fuel light to come on when only 16-17 gallons had been consumed. *slc
FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
08/31/20004
 Fuel cut off switch would cut off without any warning while driving. this has happened at least 4 times. has taken vehicle to dealer each time. it was repaired the first time it happened. the last 2 times been in contact with dealership & nothing was informative about problem. vehicle died out. got out of vehicle & turned switch back on to start vehicle again. *ak
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM
08/05/2002
 While being driven at45 mph, van stalled, resulting in steering wheel locking and brakes completely failing with no pressure. owner had no other choice but to coast through an intersection with light. please describe details. *ak
11/13/2000604/01/1998
 Vehicle is experiencing a stalling problem, dealer has replaced the alternator and performed tsb 982506, however problem is still occurring, a customer service rep from ford was supposed to call consumer back regarding problem and has not. *slc consumer states he has since discovered that the problem with the vehicle is an engineering defect in the fuel injector causing the engine to shut down at slow speeds when the vehicle is turning.*jb
06/15/2000802/01/2000
 Recurring problem concerning the fuel system, often when we reach about a quarter tank of fuel about the time the low fuel light comes on if we come to a stop the vehicle will cut off and it will blow the fuse that controls the fuel system and after replacement of the fuse it will continue to blow until we put in more gas
04/03/2000
 Fuel will leak when filling up gas tank to full, possibly due to failure of o-ring. tank still leaked after o-ring replaced. owner has not replaced tank. *ak *ml
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM - FUEL RAIL
 Exit line from the fuel injection system is leaking fuel onto the engine , causing a very strong gas odor in the vehicle. this could lead to a fire. please give any further details. *ak
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM - INJECTORS
05/10/2004303/01/2000
 Dt: the contact states while driving for about five or ten miles ,if the contact goes to make a right turn or stop, the vehicle will stall. this occurs while decelerating. he states that everything works fine while he is driving the vehicle. it just when he goes to stop that he has the problems. he took the vehicle to his personal mechanic , and they replaced the idle control ,and cleaned the injectors. however, vehicle still has this problem. the vehicle shuts off with no warning. it will start back up as soon as it stalls when he puts it in park. the contact states that this has happened more than 100 times. vehicle has automatic transmission. the vehicle is regularly maintained. it started about a year ago and it wouldn't do it all the time and now it is doing almost every time you slow down. has came very close to causing an accident.*ak
FUEL SYSTEM, GASOLINE - STORAGE
12/09/1998
 Vehicle has a bad seal on the fuel cap. vehicle was being inspected at state. dealer contacted and cannot duplicate the problem. provide further information. *ak
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
01/01/2005730001
 Consumer stated excessive fuel was leaking . dealer indicated that top of the fuel tank broke apart. *ak
11/10/2003854546
 Ford installed improper size fuel tanks which caused the wire in the fuel tank to chafe and short out which caused the vehicle to stop running. *ph the consumer believes the manufacturer should be financially responsible for repairing the problem. *nm
02/10/2004142271102/06/2004
 Fuel tank collapse on 1998 windstar dealer wants $1300 dollars to replace fuel tank and all related components. dealer says this is because there is a vacuum inside tank created by the fuel pump. perfectly running van that has been kept up maintenance wise is now inoperative do to stalling. *ak
05/01/2003700002
 Fuel tank collapsed. as a result, the 22 gallon tank can only take in 13 gallons.*ak
10/01/200350000102/20/2000
 I have a 1998 ford windstar, and its fuel tank was leaking into the passenger compartment. when brought to the dealer it was said that the fuel tank collapsed at the fuel pump, which caused the leaking. *la
12/28/2002650001
 Fuel tank broken / punctured when ran over on a unknown object (suspect tire piece) during night on a rainy day. *jb
11/14/20029133409/22/1997
 1998 ford windstar. according to dealer repair dept there was a hole in the fuel tank caused by corrosion relating to the emission tubing. had to replace fuel tank. reported to ford, they have nothing to report. dealer person said they have replaced several of these and this is in a small rural town. tank was back ordered for a month. i would think that a hole in a gasoline tank would be hazardous, and given the statement of seeing several of these in one dealership plus the backorder situation indicates this is a widespread problem.
09/17/2002102/01/2001
 our fuel pump went for a second time in a three month period. the cause of the fuel pumps malfunction was a short in the wiring which was caused by the fact that the depth of the fuel tank was not within the required specifications. the depth of the fuel tank was only 6 5/8 deep. if the depth of the tank is to shallow, the wiring atop the fuel pump can become chaffed on the metal fuel hose clamp. ford had issued a service bulletin on this very issue. what occurred with our van was precisely what the service bulletin warns of. the service bulletin states that if thefuel tank depth is less than 7 3/4 replace the fuel tank 9002 and fuel delivery module 9h307. our van clearly met that criteria, however, ford would not replace the fuel pump or fuel tank at fords expense. the service manager and technician at ford stated that if i were a regular customer of duddie ford, that they would not let me take the van with me because of the safetyissues involved. when i asked what exactly they meant, they stated that because of the chaffing of the wiring on the fuel pump, a short could occur, which could ignite gasoline fumes and therefore result in a catastrophic tragedy. basically, the van could explode. an appointment was made at granite ford in rochester, new hampshire for replacement of the fuel tank per the service bulletin. the granite ford technician also measured the depth of the fuel tank and found a depth of only 6 5/8. (see granite ford invoice) the fuel tank was removed and replaced. dt
07/20/20022003/01/2098
 Engine stalled; reported to sheehy ford; replaced sensor; within a week vehicle stalled again and often. reported to dealer; could not duplicate stall condition. stalling occurred up to 13 times a day; returned vehicle to dealer. after two days dealer found that plastic gas tank had collapsed, causing a vapor lock, affecting fuel flow to engine and resulting in stalls. gas tank replaced at cost of $882.*ak
06/29/2002102/01/2002
 Fuel clapsed while on vacation blowing fuses and ruining fuel pump had to have both replaced. ford claimes has had no other problems with this. *ak
 Fuel tank is leaking, causing a fire hazard. please provide further information.*ak
02/01/200001/01/1998
 1st to 2nd bang when shifting on slow acceleration (repeats often), fuel pump continually cuts out when parked on slight downhill, still 6+ gallons left. only since replacement of fueltank and gas pump due to electrical short
12/12/199810012/01/1998
 We have been to arbitration on this defect. we have the 25 g. gas tank and ford says the misreading is supposed to be the way it is.
09/01/1997
 Gas gauge.
 Fule tank sending unit is leaking fuel. the dealer has been notified. *ak
06/01/1999106/01/1999
 Noted problem only when gas tank was filled, smelled gas, thought it was from vent line - after a few more tank fills - noticed gas leaking on ground during tank fill-up. problem was fixed 07/29/1999 at brown motors petoskey, mi - this could be a vary serious problem - could cause fires at gas station, home garage's, ect. this problem was there when we bought the van as it was never full during test driving - started smelling gas fumes when we would fill tank up and untill the fuel level would drop down low enough not too leak out the o-ring seal.
 Fuel gauge inaccurately reads the amount of fuel in the vehicle. the dealer says that the problem is normal. *ak
205/01/1997
 Air lock on filling gas tank, after repair attempts still continues. nlm
04/01/1998
 We purchased an optional 25 gallon fuel tank. when the fuel gauge pointer bottoms out at e and the low fuel light comes on, we fill the tank and are only able to put approximately 18 gallons in the the tank (on a regular basis). the owner's guide says that the light should come on when there is 1/16 of a tank (1.5-2 gallons) left as a reserve. we have had the van into two different dealers for a total of 8 times but they have not fixed the problem. the dealers have replaced the sender assembly twice, the fuel gauge assembly and the fuel tank assembly twice. the dealers state that there is nothing that they can do; they have done all that ford has authorized. ford says that this is a problem that the dealers should handle. we feel that it is unsafe for my wife and children to travel in a vehicle that may run out of gas on a busy highway (possibly causing an accident) or in the middle of nowhere(leaving them stranded and unsafe). we feel that a gauge as important as a fuel gauge should be accurate and consistent. *ak
01/30/1998701/01/1998
 Neither dealer nor ford zone rep helpful. probable cause of tank collapse is failure in vapor/vent system to fuel tank. see also your odi id 829866. problem appears to be limited to 1998 windstar with 25 g tank. dealer has found orig tank crushed, has replaced same, has replaced/checked gauge sender, and replaced gauge. probelm continues as originally reported, and believed to be related to vacuum in tank as pump extracts fuel, and external air pressure plus internal tank vacuum crushed 25 g tank to 16 g volume.
09/05/1997
 Fuel gauge reads inaccuratly. the fuel gauge reads empty even when there is still 1/4 tank or more fuel.
12/10/1997
 While driving the fuel system doesn't let know how much fuel is in the tank. the vehicle has been in the ford repair shop four times. dealer cannot deterimine what the promblem is. *ak
06/06/1998306/01/1998
 The consumer has experienced problems with gas tank. the consumer statevehicle doesn't hold the capacity of gas that is stated on the sticker. the gas tank gauge will read empty when it has 4+gallons gas. the manufacturer has been to be contacted. two repair attempts and both failed and currently third repair has been postponed due to lack of parts. the transmission has developed a second leak. *ak.et.
04/04/1998
 After dealer did the recall for the fuel tank sensor, there was a gas smell which was caused by a pin hole in the gas tank. dealer replaced gas tank with a new plastic gas tank. 45 days later, the vehicle had a gas leak caused by a pin hole in the gas tank, in which if there was a source of ignition a fire could have occurred. *ak
05/20/1998
 The fuel tank was punctured after running over a dead turtle in the roadway and fuel leaked profusely from damaged area. the tank was found to be plastic and had not type of protective shields.
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY - FILLER PIPE AND CAP
12/01/200437000304/13/2000
 Concerned about fuel tank filler hose. check engine light comes on states loose fuel cap. fuel cap has been replaced three times. problem persists. is there a 1999 recall on windstar fuel tanks? what does it entail? we are the original owner of the vehicle.*ak
01/01/2000
 Filler nozzle cracked and there was fuel leaking from vehicle. contacted a dealer, and dealer was not willing to do anything.*ak
05/15/199803/01/1998
 Fuel spitting back out of filler neck while filling fuel tank. dealer notified, and informed consumer that vehicle's problem was not covered under manufacturer's recall. *ak *ml
FUEL SYSTEM, OTHER
1
 Fuel pump fuse has blown on 1998 ford windstar. *mr the vehicle ceased to run while in heavy traffic. the consumer found that it ha been a number of vehicle's with fuel pump wire failures due to defective venting systems for the fuel tank. this causes the fuel tank to deform, collapse and pinch the wires to the integrity mounted fuel pump. *sc
12/05/2003800001
 Consumer noticed something hanging down from the vehicle while it was sitting in the driveway. upon closer inspection consumer found that the vapor recovery system bracket rusted.*ak
08/11/1998508/01/1998
 Problem originated immediately after purchase. was taken in 3 times for repair. fuel gauge would not register full when filled and filling up with only 12 to 14 gallons when at 1/4 of a tank or less. problem supposedly fixed but still had occasional erratic movement and improper fuel gauge readings over a period of 1 1/2 years. problem became much worse in july 2000. had erratic movement in fuel gauge, would fill tank, gauge would go to full, then drop 1/8, then go back up to full, the drop 1/8 again. filling up at 1/4 of a tank or less with 12 to 14 gallons again. vehicle has been at dealers 5 times, to date. continually say that it is fixed but when i fill up with gas the problem is still there.
07/19/2000302/01/1997
 Driving fwy speed, left most lane, gas guage read over 1/4 tank, vehicle was really out of fuel (empty) and stalled in left lane with heavy traffic. was repaired 2x previously by dealer, dealer insists there's no problem. *ak
05/01/1997103/01/1997
 Gas gauge failed.
09/30/1997409/01/1997
 Vehicle supposedly has 25 gallon gas tank. will not accept more than 15 gallons when dash light indicates low fuel ( 1/16 tank ). dealer has replaced tank 4 times, done several tsb procedures. manufacturer notified. still not resolved. *ak
06/06/1998306/01/1998
 The consumer has experienced problems with gas tank. the consumer statevehicle doesn't hold the capacity of gas that is stated on the sticker. the gas tank gauge will read empty when it has 4+gallons gas. the manufacturer has been to be contacted. two repair attempts and both failed and currently third repair has been postponed due to lack of parts. the transmission has developed a second leak. *ak.et.
09/05/19971
 While driving vehicle it ran out of gas. had coasted to side of road. fuel gauge showed fuel in tank, but was informed no fuel in tank. *ak
FUEL SYSTEM, OTHER - DELIVERY - FUEL PUMP
10/09/200384554303/18/2000
 Vehicle blows fuel pump fuse and stops running. this has occurred in 3 instances on the highway and in the middle of an intersection. *ak
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
01/25/200201/15/2002
 Car stalls and cuts off when slowing down to stop - making sharp turns - when completely filling gas tank up - at the half way point on fuel gauge
01/23/2002107/01/1999
 I was informed that the problem was recalled in 1998. i inform the local dealer of of this recall and asked if this problem could be fixed. he stated that the recall has expired and that the ford dealership would not pay for this. i feel that since i was not notified of this at anytime. i was not able to take the vehicle in to get fixed. the infomation pertaining to this is: 97b17 (program number) issue date: feb 98 recallm - fuel gauge/sender assembly. reason for this program: the fuel gauge in the instrument cluster of your vehicle may read approxiamately 1/4 full when there is very little fuel in the fuel tank. this could cause you to experience the inconvenience of running out of fuel i have a copy of a letter that my repair man has given me to see if the dealer ship would fix the problem. we have one vehicle and have three children. i can't relie on this vehicle at this time. i am afraid that the vehicle would stop all of a sudden and then an accident may occur. thank you for your time. monica mcclurep all of
11/01/1998105/01/1998
 Gas tank sensor unit failed. yh