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For those keeping Taurus’s for over 100,000 miles, please take note. Springs on struts do fail and they are capable of taking a life.
A couple of days ago I was about to back away from my garage in my 2000 Ford Taurus Wagon. I backed up a few inches and heard a lot pop and the driver’s side tire lost all of it’s air. Today I set up the floor jack on the gravel and lifted the car. After unbolting the car I had trouble pulling the wheel off.

Looks like the front driver’s side spring broke and pierced the tire. I was about to take the car on a two lane highway busy with semi’s.
The spring broke at the lower pad and a chunk looking like a round horseshoe broke off. The struts and springs were original and the car has 150,000 miles. Had this happened on the highway it could have been catastrophic.

I think at this point the car is going to the wreckers. I can get a $1,000 CDN coupon towards an E bike for a family member. There is serious rust underneath the plastic rocker covers so I was already planning to junk it some day.


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Discussion Starter #2
More shots. I found the chunk of spring on the bottom mounting plate. The spring expanded past to below the plate.
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I have had 4, now 3 in my herd. 3 of the 4 broke springs, and my Taurus, I replaced the front struts when I bought it at 107K and it is a very low rust car. Pic of a rear spring, that broke on the bottom, but this pic shows the plastic coating fails, and water gets under it and eats up the spring. There are trucks with no coating on the springs, and they rust but do not break. the issue is local rust pitting under the plastic. It is not only G-4, a friend had '92 break and puncture the tire and the car was under warranty. Dealer replaced the struts and the tire. And I also had '95 break so it is not just G-4. Plastic coating works great to keep the OE spring rate and not sag. But Ford has an issue with coating quality and did not fix it.
-chart-
 

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Had my front springs on my 1993 and 2001s replaced under the recall from Ford. The one 2001 broken a second time but the recall required that they install a metal cup on the bottom of the strut to retain the spring from hitting the tire. Had one rear spring break a 40k miles on my 2001. Had two front springs break. I was surprised after my 93 recal that they didn't fix the problem on the 2001s from factory with the retaining cups at least in the rust belt.
 

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Pic of the spring catcher. Ford put this on my '95. Strange all my spring bk happened very close to home. My fear when far from home, spring bks or Alt quits.
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Good info. I replaced the springs on both my '99 wagon and sable at 125K, I'm in NC so very little rust on the cars.
 

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Bought a 2002 Sable wagon a couple years ago. The front driver's side spring went bang! as I was backing out of the driveway. Needed new struts anyway. But, damn, I was just glad it didn't happen while I was on the road!

In hindsight, I hit a speed bump at nearly 30mph a couple weeks before (paint had faded). Mighta been a contributing factor ...
 

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My 96' has almost 300K on it with original springs. I am in Utah. I guess I had best inspect the springs.
As a fellow Utahn the climate is pretty forgiving, cars rust but they take WAY longer than they do back east. Generally speaking though, if the springs have lost all their paint and are just rusty looking throughout the whole coil, you might as well change them. The strut is also likely worn as well.
 

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Definitely drives better now :--) Per all the recommendations on this board, I went with the KYB struts (vs. Monroe) and the handling is good. The price difference was about $50 per side. So not a big factor in the overall job cost.

I had a 2004 Taurus wagon that I replaced tired struts on. Don't know the brand, but they were terrible and I had to get different ones. Point being, the brand matters in this case.
 
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