In 1995, Ford released its first conventional minivan, the Windstar. The 2000 Windstar came standard with an independent suspension system on the front to help aid in handling and ride quality. This system consisted of a strut assembly, spindle assembly, stabilizer bar with links and a lower control arm. The lower control arm ties the lower part of the Windstar’s spindle to the van’s subframe assembly. Replacing the lower control arm is relatively simple and straightforward.
Loosen the lug nuts on the wheel with the failed control arm using a ratchet and socket. Raise the front of the van with a floor jack and slide jack stands under its subframe. Lower the van. Remove the front lug nuts and pull the wheel off the front hub.
Remove the nut from the steering knuckle-to-ball joint pinch bolt using a ratchet and socket as you hold the pinch bolt steady with a combination wrench. Remove the pinch bolt.
Insert a 12-inch pry bar between the lower control arm and the subframe and pry downward to pop the lower ball joint free from the lower control arm.
Remove the nut from each of the two-control arm-to-subframe bolts using a ratchet and socket as you hold each bolt steady with a combination wrench. Pull the lower control arm from the Windstar.
Guide the inner part of the control arm into its brackets on the subframe, aligning the bolt holes in the control arm’s bushings with those in the subframe’s brackets. Slide the bolts through the bolt holes so the rearmost bolt’s head faces the front of the Windstar and the front bolt’s head faces the rear of the van.
Hand-tighten the control arm-to-subframe nuts onto the bolts.
Pivot the control arm upward and guide the ball joint stud into its hole on the bottom of the spindle assembly. Guide a new ball joint pinch bolt through the bolt hole in the bottom of the spindle and hand-thread a new nut onto the bolt; the new bolt and nut come with the new control arm. Torque the nut to 46 foot-pounds while you hold the pinch bolt steady with a combination wrench.
Install the wheel back onto the front hub and hand-tighten the lug nuts. Raise the van off the jack stands with a floor jack and remove the jack stands. Lower the van to the ground and torque the lug nuts to 100 foot-pounds with a torque wrench and socket.
Tighten the control arm-to-subframe nuts to 98 foot-pounds with a torque wrench and socket as you hold the bolts steady with a combination wrench. To provide extra working space, turn the wheels left or right as needed.
Take the Windstar to a local auto repair facility to have an alignment performed.
