I turned the air conditioning on in the van and after about 10 minutes, turned it to the 'max ac' position. The hood started steaming so I turned the air completely off. After less than a minute, I noticed the hood was smoking so I pulled to the side of the road immediately. I turned the car off and exited the van and saw that the passenger side of the hood was on fire. I ran to the passenger side and opened the sliding door, and got my 18 month old and 4 year old out of the vehicle. After we were all a safe distance away I saw that most of the hood of the van was in flames. By the time the fire department arrived about 5 minutes later, the entire hood was on fire with a lot of black smoke. The entire engine compartment looks charred and partially melted. The vehicle is beyond repair. I'm thankful my children are safe but I am very concerned about the safety (failure) of this vehicle.

- Redford, MI, USA

At 150,000km (94,000 miles) was in for front spring recall and dealer recommended engine front gasket replacement. Immediately had this repair done ($900 cdn). Shortly after my mechanic stated that he could hear a slight knocking and predicted the engine bearing would go within the year. I started campaining with Ford based on the history of gasket failure (coolant leaks past gasket into oil causing bearing failure). Ford customer care said they need a dealer to diagnose the problem so had a dealer check it out with no problem found. At close to 170,000km (106,000 miles) the knocking became louder and the oil light began to flicker. Again contacted Ford who asked for dealer diagnosis which I did and confirmed need engine replacement. Ford customer care said there were no programs for my vehicle therefore no coverage but would consider partial payment as good will gesture if repaired at a Ford dealer. Continued to email Ford but they stopped responding to my concern. Had the engine replaced at my mechanic.

- Waterloo, UN, USA

At a routine nys inspection, the Ford dealer advised that the head gaskets needed to be replaced. The car is 6 years old with 36K miles. Called Ford for assistance, and got profuse apologizes, and no help with a $1600 repair. The car is exhibiting no symptoms of any problems, and I do not have the money for the repair. For such low mileage, I think that fmc should make some attempt to assist with this complaint. They are certainly aware of the problem with the 95 & 96 Windstar!!

- Levittown, NY, USA

I bought this 1997 Ford Windstar in March of 2003. The very next day I returned to the independent car dealer due to the check engine light was on. They said nothing was wrong and they reset the light. Within a week it was on again and this time they said it was a fluxation in the electrical current and it was making the light come on. They reset it. About 2 weeks later it is losing coolant somewhere and running rough, they check it and now it needs 2 out of 4 oxygen sensors replaced im told. They pay for it if they truly fixed it because about 2-3 weeks later I am havint the same problems so they replace the other 2 oxygen sensors, but cannot explain the coolant loss. Ever since I have had nothing but problems so I decided to go to the local Ford dealer even though I try to avoid dealers because of prices and they charge me $58 to tell me I need a head gasket, my ABS system is not working, timing cover is leaking, ball bearing is shot and my antifreeze looks like mud. This is all wrote on a service estimate I asked them for. It would cost about $1700 + tax for them to fix. I have read that Ford knew they had a problem with the 95 Windstar and the head gaskets and offered an extended warranty or money towards a new car so I feel they know all Windstar with this 3.8L engine are faulty not just the 95's. I called Ford and they told me tough luck basically. I have read on the internet numerous complaints about the head gaskets in all 3.8L Windstar and I want my van fixed.

- Boswell, PA, USA

I own a 1997 Ford Windstar minivan (VIN# [xxx]) that contains a 3.8 V6. At 82,000 miles, the head gasket has blown. The dealer tells me that it will cost between $2000 and $4000 to repair. After doing extensive research on the web, it appears that the 1995 and 1996 models also had head gasket problems due to an admitted design flaw. Ford claims to have corrected the problem-but there are increasing numbers of owners of 1997 models that are experiencing the same problem. Repeated visits to the dealership-as well as numerous calls to Ford-have resulted in dead ends. I get responses such as: The warranty has expired, there are no recalls on your vehicle at this time, etc. But since this is clearly due to a design flaw in the engine, then shouldn't this still be covered and corrected" Ford offered a brief program to repair the earlier models-so why hasn't this been offered on the later years" Ford claims that they have fixed the problem-which they clearly have not-yet they expect people to simply pay for the repairs. I believe that Ford needs to be held accountable for this, and that they should offer to perform the work at either a discounted rate, or for free since this is due to their engine design. Even the manual claims the head gasket is expected to last for at least 120,000 miles, and I was told that this was the case with this vehicle. Had I known of the problems other owners were having, I would have reconsidered my decision to purchase this van. To that end, I feel that I was misled somewhat. It is my hope to have Ford admit to the problem and offer to repair my vehicle at no charge. Given the circumstances-and the amount of evidence supporting the claim of negligence on the behalf of Ford-this should not be an unreasonable request. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Palo Alto, CA, USA

Head gasket leaked, timing cover cracked. $3,000 + repair bill.

- Huntsville, AL, USA

The engine over heated.

- Bloomingdale, IL, USA

97 Windstar has head gasket failure im still paying on it purchades at avis Ford of southfield 12 mile telegrap mi cannot afford fixin it I believe is a manufacure failure and need to be fix do not have any safer transportation available at this time please hel

- Ann Arbor , MI, USA

While driving, the consumer turned the ignition off. Upon starting the vehicle again, the starter made a funny noise. Also, the thermostat was extremely high. The consumer had taken the vehicle to the dealer, and the problem was not resolved. The consumer stated that the radiator was opened and the anti-freeze was low-refilled. The mechanic thought it was the water pump. The head gasket was leaking.

- Kirkland, NY, USA

While driving temperature gauge will point to hot, causing tvehicle to overheat. Consumer will have to pull over. Dealer notified.

- Ronkonkoma, NY, USA