At 70,000 Km, the rear shocks were shot.
At 80,000 Km, the head gaskets blew. All but a $100 deductable of the $2,400 repair cost was covered by the used car warranty provided by the dealer (not Ford).
At 130,000 Km the timing cover gasket had to be relaced due to a crack causing a coolant leak - 10 hours to replace & almost $1,000!
The transmission shifts hard and erractically at times - this could spell future trouble.
The stock aluminum wheels leak like sieves, constantly requiring resealing.
Standard ford radio/cd player is ditzy.
Early signs of rust on the sliding door & lower panels (I drive in a Winter zone) - for now under control with a rust preventative oil spray every year.
A comfortable, fast people-hauler with very comfortable seats (quad leather captains chairs).
Cabin noise is on the high side.
Relibility could be better.
Service costs high (due to engine placement - a common mini-van problem).
I have had some of the problems you describe, expenses continue to mount on our 96 windstar. Please contact me, I understand you are Canadian, reach me at kevin.smith6@sympatico.ca.
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