2004 FORD FREESTAR

5 recalls, 1,600 complaints - 87 TSBs

SEATS

Defect Description

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massac... Read more

Consequence

In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.

Remedy

Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.

196,667 vehicles affected

Manufacturer: Ford Motor Company

POWER TRAIN:AUTOMATIC TRANSMISSION

Defect Description

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.

Consequence

THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.

Remedy

FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

206,452 vehicles affected

Manufacturer: FORD MOTOR COMPANY

FUEL SYSTEM, GASOLINE

Defect Description

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE... Read more

Consequence

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy

UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

58,640 vehicles affected

Manufacturer: UFI FILTERS USA

WHEELS:HUB

Defect Description

CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB.

Consequence

IF THE CRACKS WERE TO PROGRESS, THIS COULD EVENTUALLY RESULT IN WHEEL SEPARATION. WHEEL SEPARATION MAY LEAD TO LOSS OF VEHICLE CONTROL, AND POTENTIALLY RESULT IN A VEHICLE CRASH.

Remedy

DEALERS WILL REPLACE THE FRONT HUB, ROTORS, AND WHEEL BEARINGS. THE RECALL BEGAN SEPTEMBER 20, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

34,013 vehicles affected

Manufacturer: FORD MOTOR COMPANY

STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

Defect Description

ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.

Consequence

IF THIS LINE BECOMES DISCONNECTED, IT MAY CREATE THE POTENTIAL FOR FLUID TO COME INTO CONTACT WITH THE EXHAUST SYSTEM, WHICH COULD RESULT IN SMOKE OR FIRE.

Remedy

DEALERS WILL INSPECT THE POWER STEERING LOW-PRESSURE LINE TO ENSURE THAT IT IS SEATED PROPERLY AT THE RACK AND PINION STEERING GEAR. OWNER NOTIFICATION BEGAN NOVEMBER 10, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

23,996 vehicles affected

Manufacturer: FORD MOTOR COMPANY

Complaint Statistics

1,600 total complaints 26 crashes 17 fires 29 injuries 1 deaths

Top Reported Components

Component	Complaints
POWER TRAIN:AUTOMATIC TRANSMISSION	495
POWER TRAIN	304
ELECTRICAL SYSTEM	115
SEATS	84
ENGINE	68
STRUCTURE:BODY	63
POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	50
ENGINE AND ENGINE COOLING	35
VEHICLE SPEED CONTROL	29
UNKNOWN OR OTHER	26

Incident date: Jun 26, 2025

The contact owns a 2015 Land Rover Range Rover. The contact received notification of NHTSA Campaign Number: 24V840000(Steering); however, the part to do the recall repair was not yet available. The contact stated while driving at an unknown low speed, the front driver's side suspension failed, rend... Read more

Incident date: Jul 2, 2025

The contact owns a 2016 Hyundai Tucson. The contact stated that while driving on the highway at 55 MPH, the vehicle lost automotive power and started vibrating abnormally. There were no warning lights illuminated. The contact pulled over and was able to restart the vehicle. The vehicle was taken to ... Read more

Incident date: Aug 25, 2024

Incident date: Aug 25, 2024

All the warning comes on the dashboard randomly. I took it to the service, they said they reset the system. However, today, my daughter was driving to her school. Again, all the warning lights came on and the car braked itself. This is a very dangerous as my daughter is a new driver. I made another ... Read more

Incident date: Mar 18, 2024

I was on the highway ramp picking up speed, and the car suddenly started to loose thottle. I pulled over to the side and the car went limp. The car shut off. I attempted to turn on the vehicle and it would not. The car was taken to an Alfa Romeo dealership and they confirmed that the fuel pump and f... Read more

Incident date: May 1, 2023

The contact's mother owns a 2019 Ford EcoSport. The contact stated that while driving at approximately 45 MPH, the vehicle lost motive power. The low oil pressure chime and message were displayed on the instrument panel. The contact called an independent mechanic who had changed the oil prior to the... Read more

Incident date: Dec 16, 2022

i am slowly coming into the driveway. All of a sudden the car accelrated while i was applying brake. the air bags didn't come on either. it hit the car in front which then got pushed into the garage

Crash

Incident date: Sep 9, 2022

The transmission is grinding and popping when shifting gears.Also it has started not moving when I shift it into drive and 3rd and 1st.When I drive it I have to put it in 1st gear and change up to drive and it grinds and pops when giving it gas to go.It comes to a crawl going up hills.Has a big loss... Read more

Incident date: Sep 9, 2022

- I have a repeated low mileage failure of the antilock brake system hydraulic control unit. The faulty unit is still installed on the vehicle. - The ABS hydraulic unit failure intermittently renders the ABS system, traction control system, and electronic stability system inoperable for varying dur... Read more

Incident date: Sep 9, 2022

Incident date: Aug 5, 2022

I just purchased the vehicle used and recently discovered there was a recall on these vehicles. The vehicle I purchased keeps stalling and is not getting any power. I’ve had the vehicle checked by the car lot and they say there is nothing wrong.. the vehicle died out on me already twice while I wa... Read more

Incident date: Feb 5, 2022

The contact owns a 2004 Ford Freestar. The contact stated while driving approximately 55 MPH, the vehicle started losing motive power. The contact depressed the accelerator and the vehicle continued to slow as the RPM was rising. The contact did not notice any warning lights illuminated. The contact... Read more

Incident date: Feb 15, 2022

Transmission slip , leaks , loosing ofpower, shakes from 45 mph to 55 mph , mechanic shop says it is the Torque Converter that is malfunction.

Incident date: May 13, 2021

the van has less than 49k miles on it and the reverse has not worked but it will drive forward. Others have had this issue as well.

Incident date: Sep 1, 2021

The contact owns a 2004 Ford Freestar. The contact stated while driving 35 MPH, the vehicle began to stall. The contact stated no warning light was illuminated. The contact was able to restart the vehicle and drive to his destination. The contact took the vehicle to an independent mechanic and was i... Read more

Incident date: Jun 1, 2021

The contact owns a 2004 Ford Freestar. The contact stated that the third-row seat floorboard was corroded with several holes. The TPMS warning light was illuminated. The contact received notification of NHTSA campaign number: 13V081000 (Seats) however, the part to do the recall was unavailable. The ... Read more

Incident date: Mar 26, 2021

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT WHEN PLACING THE VEHICLE INTO ANY GEAR, THE VEHICLE WOULD STALL WITHOUT WARNING. THE CONTACT CALLED ALL AMERICAN FORD OF HACKENSACK (520 RIVER ST, HACKENSACK, NJ 07601) WHERE HE WAS GIVEN A DIAGNOSTIC FEE. UPON INVESTIGATION, THE CON... Read more

Incident date: Mar 2, 2021

I READ THE RECALLS FOR 2004 FORD FREE STAR TRANSMISSIONS AND MY VAN WITHOUT WARNING JUST QUIT WORKING IN THE MIDDLE OF THE ROAD WHILE I WAS DRIVING. I COULD GET IT TO START BACK UP FOR A SECOND TO MOVE IT TO THE SIDE OF THE ROAD, BUT IT WOULDN'T START AFTER THAT.

Incident date: Feb 12, 2019

PCM HAS ISSUES DO TO MOISTURE WHICH AFFECTS ELECTRICAL SLIPPING GEARS ABS SENSOR PROBLEM POWER STEERING ISSUES AND TCM AND THIS VEHICLE HAS ALL SAFETY PROBLEMS ACCORDING TO RECALLS NONE OF IT WAS FIXED BECAUSE FORD SAYS YOUR VIN NUMBER IS NOT ON LIST.

Incident date: Feb 12, 2019

Incident date: Mar 1, 2020

I JUST CAME ACROSS THIS WEBSITE AND WISH I WROTE THIS A YEAR AGO BECAUSE I WOULD HAVE MADE A COMPLAINT THEN. I HAVE HAD MANY ISSUES WITH THE LIGHTS FLICKERING, COMING ON AUTOMATICALLY WHEN IT RAINS, MY INTERIOR LIGHTS STAYING ON AND ACTUALLY CATCHING FIRE BECAUSE IT HAD GOTTEN SO HOT. MY RADIO USED ... Read more

Fire

Incident date: Nov 12, 2020

THE PART THAT HAS THE CLIP FOR BACK SEAT FELL OUT AND NOW THERE IS A 5 BY 5 INCH HOLE GOING INTO THE WHEEL WELL AND THE SEAT HAS NOTHING TO CLIP ONTO AND BE SECURE, THIS WAS RECALLED IN THIS MODEL

Incident date: Nov 12, 2020

THE PART THAT HAS THE CLIP FOR BACK SEAT FELL OUT AND NOW THERE IS A 5 BY 5 INCH HOLE GOING INTO THE WHEEL WELL AND THE SEAT HAS NOTHING TO CLIP ONTO AND BE SECURE, THIS WAS RECALLED IN THIS MODEL

Incident date: Sep 29, 2020

THE VEHICLE WAS IN MOTION ON A HIGHWAY AT A SPEED OF 55 MPH WHEN IT HAD INSTANT TRANSMISSION FAILURE. PULLED OVER TO THE SIDE OF THE ROAD. VEHICLE WOULDN/T MOVE IN ANY DIRECTION OR GEAR. TRANSMISSION WAS IN PROPER FLUID LEVEL RANGE.

Incident date: Aug 7, 2020

DRIVING DOWN RD N IT FELT AS IF SOMEONE WAS PUSHING BREAK WHILE I WAS SMASHING GAS PEDAL . LOST ALL FIRE TO CAR WOULDN'T GO NO WHERE. I WAS ON A COUNTRY RD GOING UPHILL. IT SPOTS N SPUTTER N JERKS REAL HARD GOING UP HILL LIKE MY TRANSMISSION GOING BAD BUT MOTOR SOUNDS GOOD SO I HAVE NO CLUE..

Incident date: Aug 7, 2020

Incident date: Jul 9, 2020

I WAS DRIVING DOWN THE HIGHWAY AT APPROXIMATELY 45 MILES PER HOUR WHEN ALL OF A SUDDEN MY RPMS SHOT UP BUT I HAD NO ACCELERATION IT DID THIS WITHOUT WARNING I MANAGED TO GET OVER TO THE SIDE OF THE ROAD, AND I WAS GOING TO CHECK TRANSMISSION FLUID BUT WHEN I PULLED THE DIPSTICK OUT FLUID SHOT OUT TH... Read more

Incident date: Feb 16, 2020

TORQUE CONVERTOR DEFECTIVE IN SIMILAR FORD FREESTAR MODELS EDDY'S FORD DEALERSHIP SOLD RECALL VEHICLE AS IS AGAINST STATE & FEDERAL LAWS AND LIED TO DISABLED VETERANS ABOUT REPLACING THE DEFECTIVE TORQUE CONVERTER AFTER DISCOVERY OF RECALL CAUSED PISTON HOLE ENGINE BLOCK AND TRANSMISSION DAMAGE CUTT... Read more

Incident date: Feb 16, 2020

Incident date: Feb 1, 2020

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS, THE STEERING WHEEL VIBRATED AND STARTED PULLING TO THE RIGHT. THERE WAS NO WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND THE CONTACT WAS INFORMED THE SUBFRAME OF THE FRONT... Read more

Incident date: Jan 13, 2020

MY FIANCE WAS DRIVING TO WORK WHEN SHE HEARD A CLICKING NOISE THEN A LOUD BANG COME FROM THE TRANSMISSION, SHE LOST ALL POWER, IF SHE HADN'T RESPONDED TO THE SITUATION AND TURN IMMEDIATELY INTO A CHURCH DRIVEWAY SHE WOULD HAVE BEEN REAR ENDED! THE VAN WAS IN MOTION DRIVING SOUTHBOUND ON 257TH ST... Read more

Incident date: Dec 17, 2019

I HAVE SPENT SO MUCH MONEY IN THIS VAN THAT I WOULD LIKE TO REPORT THESE ISSUES TO YOU FIRST IT WAS THE FUEL FILTER AND NOW IT'S THE TRANSMISSION I KEEP THE MAINTENANCE UP AND THINGS STILL GO WRONG

Incident date: Dec 17, 2019

I HAVE SPENT SO MUCH MONEY IN THIS VAN THAT I WOULD LIKE TO REPORT THESE ISSUES TO YOU FIRST IT WAS THE FUEL FILTER AND NOW IT'S THE TRANSMISSION I KEEP THE MAINTENANCE UP AND THINGS STILL GO WRONG

Incident date: Dec 17, 2019

I HAVE SPENT SO MUCH MONEY IN THIS VAN THAT I WOULD LIKE TO REPORT THESE ISSUES TO YOU FIRST IT WAS THE FUEL FILTER AND NOW IT'S THE TRANSMISSION I KEEP THE MAINTENANCE UP AND THINGS STILL GO WRONG

Incident date: Nov 3, 2019

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. WHILE ADJUSTING THE THIRD ROW SEAT, IT DETACHED DUE TO CORROSION. THERE WERE NO WARNING INDICATORS ILLUMINATED. TRI COUNTY FORD (032 COMMERCE PKWY, LA GRANGE, KY 40031, (866) 417-0262) WAS INFORMED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. ... Read more

Incident date: Nov 15, 2008

2004 FORD FREESTAR NOW.MILES 59000 PROBLEMS STARTED AROUND 45.000 MILES STARTED IN 2007 WITH BATTERY DEAD IF CAR STAT A MONTH STARTTED IN 2008 RIGHT AND LEFT LOW AND HIGH BEAM. HEAD LAMP CONNECTOR KEEP MELTING/ BURNING UP THE GROUND WIRE TRANSMISSION MAKING CLICKING NOISE IN FORWARD AND REVER... Read more

Incident date: Nov 15, 2008

Incident date: Sep 10, 2019

WE WERE DRIVING ON A 4 LANE ROAD AND MY 2004 FORD FREESTAR LOST ALL POWER TO THE TRANSMISSION. IT WOULD NOT GO IN ANY GEAR. DRN31 NOTHING JUST REVS UP! WE ALSO HAD THIS PROBLEM A YEAR AGO AND I FLUSHED THE TRANS AND IT SEEMED TO WORK UNTIL NOW. ALL FLUIDS WERE FINE ON THE VEHICLE AND LINKAGE IS ATTA... Read more

Incident date: Aug 8, 2019

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE VEHICLE DID NOT MOVE FORWARD OR BACKWARDS WHILE IN A PARKING LOT. ALSO, THE POWER TRAIN INDICATOR ILLUMINATED INTERMITTENTLY AND THEN REMAINED ILLUMINATED. THE CONTACT CALLED HART FORD LINCOLN AT 989-275-8922 (LOCATED AT 117 LAKE... Read more

Incident date: Jul 12, 2019

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE SHOOK AND STALLED. THE CONTACT PULLED OVER TO THE SIDE OF THE ROAD, TURNED THE VEHICLE OFF, AND WAITED A COUPLE OF MINUTES. ONCE RESTARTED, THE VEHICLE RAN FOR APPROXIMATELY THREE MINUTES BEFORE THE FAILURE RE... Read more

Incident date: Jun 1, 2019

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT BOTH THE DRIVER AND PASSENGER SIDE ELECTRIC SLIDING DOORS WOULD NOT CLOSE PROPERLY AND WOULD RANDOMLY OPEN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE LOCAL DEALER (DICK SMITH FORD, 7201 GARNERS FERRY RD, COLUMBIA, SC) AND THE MA... Read more

Incident date: Jun 1, 2019

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE BY AN INDEPENDENT MECHANIC, THE CONTACT WAS INFORMED THAT THE CONTROL ARM WAS PROTRUDING THROUGH THE FRAME AND CREATED A HOLE. IN ADDITION, THE CHECK ENGINE INDICATOR ILLUMINATED. THE LOCAL DEALER WAS NOT... Read more

Incident date: Jun 1, 2019

Incident date: May 9, 2019

1 MINUTES AFTER YOU START DRIVING IT LOSE POWER

Incident date: Aug 10, 2018

TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE RECALL REMEDY FOR NHTSA CAMPAIGN NUMBER: 12V006000 (POWER TRAIN) DID NOT REPAIR THE VEHICLE AND WAS NOT PROVIDED WITHIN A REASONABLE TIME FRAME. THE CONTACT WAITED FOR MONTHS TO RECEIVE THE PART FROM THE MANUFACTURER WHILE THE VE... Read more

Showing 50 of 1,600 complaints.

Technical Service Bulletins, 2004 FORD FREESTAR

87 manufacturer communications from 66 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
110000 ELECTRICAL SYSTEM	13
222000 SEATS:MID/REAR ASSEMBLY	4
162300 STRUCTURE:BODY:DOOR	3
114000 ELECTRICAL SYSTEM:WIRING	3
030000 SERVICE BRAKES, HYDRAULIC	3
220000 SEATS	3
061000 ENGINE AND ENGINE COOLING:ENGINE	3
350000 EQUIPMENT	2

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

061110 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS

061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

062300 ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

063110 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)

063130 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

060000 ENGINE (PWS)

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

061000 ENGINE AND ENGINE COOLING:ENGINE

060000 ENGINE AND ENGINE COOLING

222000 SEATS:MID/REAR ASSEMBLY

Safety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers - requests for recall service action

220000 SEATS

For 2004-2007 Freestar or Monterey vehicles Safety Recall 13S01 has been issued for vehicles that are operated in high corrosion areas for an extended period, where the sheet metal that supports the folding 3rd row seat latch strikers could

220000 SEATS

Safety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers - requests for recall service action

356000 EQUIPMENT ADAPTIVE/MOBILITY

FORD/MERCURY: SAFETY RECALL REGARDING SHEET METAL SUPPORT FOR FOLDING 3RD ROW SEAT LATCH STRIKERS CAN EXPERIENCE CORROSION AND WILL COMPROMISE MOUNTING POINT CAUSING SEAT TO MOVE. MODEL 2004-07 FREESTAR, MONTEREY. *PE

350000 EQUIPMENT

220000 SEATS

356000 EQUIPMENT ADAPTIVE/MOBILITY

FORD/MERCURY: SHEET METAL SUPPORTING FOLDING 3RD ROW SEAT LATCH STRIKERS WILL EXPERIENCE CORROSION AND COMPROMISE MOUNTING POINT FOR FORWARD PORTION OF 3RD ROW SEAT, IF VEHICLE IS OPERATED IN HIGH CORROSION AREAS FOR EXTENDED PERIOD. MODEL

222000 SEATS:MID/REAR ASSEMBLY

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

REAR CLIMATE CONTROL NOISES - SERVICE TIP. *TT

140000 AIR BAGS

RESTRAINT CONTROL MODULE DIAGNOSTIC TROUBLE CODE B2296 - SERVICE TIP. *TT

151300 SEAT BELTS:FRONT:RETRACTOR

SAFETY BELT RETRACTION SPEED. *TT

114000 ELECTRICAL SYSTEM:WIRING

SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT UPDATE. *TT

010000 STEERING

STEERING WHEEL. *EH

061000 ENGINE AND ENGINE COOLING:ENGINE

MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM). *TT

150000 SEAT BELTS

SAFETY BELT WEB STOP BUTTON SERVICE. *EH

105200 POWER TRAIN:DRIVELINE:CONSTANT VELOCITY JOINT

A BROKEN OUTER C/V JOINT ON VEHICLES BUILT BEFORE 5/1/2005. *TT

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

REAR BRAKE LINING ACCELERATED WEAR. *TT

110000 ELECTRICAL SYSTEM

WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE B1342 (RESTRAINTS CONTROL MODULE (RCM) FAULT. *TT UPDATE. *TT

110000 ELECTRICAL SYSTEM

POWER SLIDING DOORS AND POWER LIFTGATE INOPERATIVE WHEN USING THE OVERHEAD CONSOLE AND/OR REMOTE KEYLESS ENTRY TRANSMITTER OPEN/CLOSE BUTTONS - DIAGNOSTIC TROUBLE CODE (DTC) C1999. *TT

138200 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REAR WINDOW

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

110000 ELECTRICAL SYSTEM

INSTRUMENT CLUSTER DTC U1130. *EH

110000 ELECTRICAL SYSTEM

INSTRUMENT CLUSTER DTC U1262 AND OR U1135. *EH

046600 SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT

TRACTION CONTROL ABS AND PARK BRAKE LAMP FLICKER FLASH ILLUMINATE. *EH

162300 STRUCTURE:BODY:DOOR

ACCESS DOOR WRAPED OR BREAKING OFF FROM THE UNDERSIDE OF THE STEERING WHEEL SHROD. *EH

046600 SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT

TRACTION CONTROL ABS AND PARK BRAKE LAMP. FLICKER FLASH ILLUMINATE. *EH

222000 SEATS:MID/REAR ASSEMBLY

3RD ROW SEAT STRAP BREAKING. *EH

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

GENERAL POWER TRAIN CONTROL MODULE (PCM) PROGRAMMING PROCEDURES. *TT

030000 SERVICE BRAKES, HYDRAULIC

ACCELERATED REAR BRAKE WEAR. OASIS. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

100000 POWER TRAIN

4F50N TRANSAXLE NO 1-2 UPSHIFT AND DIAGNOSITC TROUBLE CODE P0732. *TT

222000 SEATS:MID/REAR ASSEMBLY

3RD ROW SEAT STRAP BREAKING (STRAP USED FOR STOWING OR ACCESSING THE REAR SEAT). *TT

021600 SUSPENSION:FRONT:WHEEL BEARING

NOISE FROM FRONT WHEEL HUB BEARING. * AR

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

100000 POWER TRAIN

GROAN/BUZZ/VIBRATION WHEN THE GEAR SELECTOR IS IN PARK WITH THE VEHICLE PARKED ON AN INCLINE. *TT THIS BULLETIN UPDATES PREVIOUS BULLETIN 17358, DATED 11/01/2003 TO INCLUDE 2005 MODELS. *TT

110000 ELECTRICAL SYSTEM

BEEPING SOUND FROM THE INSTRUMENT PANEL WHEN DRIVING AT/OVER 75 MPH, TRACTION CONTROL OFF INDICATOR ILLUMINATE WHEN VEHICLE IS NOT EQUIPPED WITH TRACTION CONTROL, AND/OR DIAGNOSTIC TROUBLE CODE B2477 (MODULE CONFIGURATION FAILURE) STORED IN

162300 STRUCTURE:BODY:DOOR

SLIDING DOOR(S) CONTACTING THE REAR QUARTER GLASS. *TT THIS INFORMATION UPDATES PREVIOUS INFORMATION, DATED 03/01/2002. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT

130000 VISIBILITY

FRONT DOOR GLASS CLICK/SNAP NOISE AT THE END OF THE UPWARD GLASS POSITION. *TT

036100 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE

DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP. ALSO INCLUDES FORD FREESTAR MY2005 AND MERCURY MONTEREY MY2005.

021600 SUSPENSION:FRONT:WHEEL BEARING

FRONT WHEEL HUB BEARING HIGH PITCHED WHISTLING/SQUEALING NOISE FROM FRONT EXTERIOR WHILE DRIVING. ALSO INCLUDES 2005 FREESTAR AND MONTEREY. *TT

030000 SERVICE BRAKES, HYDRAULIC

EXCESSIVE FRONT BRAKE NOISE. *TT

162300 STRUCTURE:BODY:DOOR

POWER SLIDING DOOR OPERATION AND DIAGNOSTIC SERVICE TIPS. *TT

350000 EQUIPMENT

REMOTE ENTRY TRANSMITTERS NOT WORKING. *TT

030000 SERVICE BRAKES, HYDRAULIC

FRONT BRAKE NOISE. *MJ

110000 ELECTRICAL SYSTEM

TRACTION CONTROL/ABS LIGHT ON WITH DIAGNOSTIC TROUBLE CODE (DTC) C1288. *MJ

138800 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:FAN/MOTOR

FRONT BLOWER MOTOR WHISTLE NOISE. *TT

114000 ELECTRICAL SYSTEM:WIRING

TRAILER TOW SERVICE KIT - SERVICE TIP. *TT

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

DEMONSTRATION/DELIVERY HOLD - SPECIAL FIELD ACTION 03L17. REVISED SMOG EMISSIONS INFORMATION. *TT

133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

FRONT WINDOW MOTORS NOT WORKING. *TT

036100 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE

TRACTION CONTROL/ABS (ANTI-LOCK BRAKE SYSTEM) LIGHT ON WITH DTC (DIAGNOSTIC TROUBLE CODE) C1288. *TT

354300 EQUIPMENT:MECHANICAL:CARRIER/RACK

ROOF RACK SIDE RAIL COVER INSTALLATION INSTRUCTIONS. *TT

110000 ELECTRICAL SYSTEM

TRACTION CONTROL OR ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LIGHT ON IN THE INSTRUMENT CLUSTER, ACCOMPANIED BY DIAGNOSTIC TROUBLE CODE C1288 (PRESSURE TRANSDUCER MAIN/PRIMARY INPUT CIRCUIT FAILURE). *TT

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

LOW TIRE PRESSURE MONITOR RESET FOR MESSAGE CENTER. *TT

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

TIRE PRESSURE MONITOR RESET PROCEDURE FOR BASE CLUSTER. *TT

114000 ELECTRICAL SYSTEM:WIRING

TRAILER TOW INSTALLATION AND WIRING HARNESS CONNECTOR INCOMPATIBILITY CONCERNS. *TT

110000 ELECTRICAL SYSTEM

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) U1130 (SCP INVALID OR MISSING DTA FOR FUEL SYSTEM) STORED IN THE INSTRUMENT CLUSTER. *TT

110000 ELECTRICAL SYSTEM

PASSIVE ANTI-THEFT SYSTEM (PATS) DIAGNOSTIC TROUBLE CODE (DTC) B1600 AND/OR B1602 WITH NO RELATED SYMPTOMS. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE U1262 (SCP COMMUNICATION BUS FAULT) AND/OR U1135 (SCP INVALID OR MISSING DATA FOR IGNITION SWITCH/STARTER) STORED IN THE INSTRUMENT CLUSTER. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION. *KB

015200 STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

POWER STEERING HOSE LEAK NEAR COOLER EXTREME COLD CLIMATE AREAS ONLY -4 DEGREES AND COOLER. *KB

010000 STEERING

ADVANCED TRACTION CONTROL SYSTEM - DURATION ACTIVATION. *KB

036400 SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT

TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288. *TT UPDATED 11/8/07. *NJ

190000 TIRES

STEERING WHEEL AND OR VEHICLE VIBRATION-VEHICLES EQUIPPED WITH GOODYEAR INTERGRITY 16 INCH TIRES ONLY. *SC

105000 POWER TRAIN:DRIVELINE

ERRATIC FLUID LEVEL READING ON TRANSAXLE DIPSTICK-LEAKS-4F50N, AX4N, AX4S TRANSAXLE. *SC

NHTSA Safety Investigations, FORD FREESTAR

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

EQ, Closed , Model Year: 2004

Stabilus Rear Liftgate Struts Failing

Please see the attached closing resume summary.It has been attached to this document as a PDF.

EA, Closed , Model Year: 2004

Corrosion of Third-Row Seat Attachment

Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, i... n the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.Read more

PE, Closed , Model Year: 2004

Corrosion of Third-Row Seat Attachment

ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplica... Read more

PE, Closed , Model Year: 2004

Service Jack Failure

The subject vehicles (SV) are all automatic transmission, front wheel drive vehicles with hand actuated mechanical park brakes. The investigation focused on allegations that the service jack failed and caused the vehicles to fall. The subject scissors-type jack appears to fail at the slotted hinge j... oints where the jack screw is located (bends at mid-point). The failures occur while the jack is in use, and vehicle movement (forward or backward) is typically reported coincident with the failure. Ford reported that most MY 2003 Windstar and all MY 2006-2007 Freestar/Monterey also use the subject jack, an additional 223,246 vehicles.NHTSA has received six consumer complaints (VOQs) involving three injury incidents and a fatality.Ford reported 26 complaints for the SVs involving an additional 4 injuries. In the fatal incident, the van fell on a person working on the engine under the otherwise unsupported vehicle; ODI was unable to determine whether the vehicle was adequately chocked or the park brake was properly set. Reported injuries include a broken arm, head and hand injuries, arm and rib bruises, and muscle strains. NHTSA has received just one new report since opening this investigation. The complaint trend in ODI and Ford data is flat if not declining.Ford provides instructions and warnings in the owner's manual, on a placard placed with the jack, and on the jack itself. These instruct consumers to put the vehicle gear selector in Park, properly set the parking brake, chock the opposite wheel, use the jack only for changing a tire, loosen the lug nuts prior to jacking, and to not get under a vehicle supported by the jack only (NHTSA also recommends that jacks only be used for tire changing).In the VOQs, roughly half the consumers were using the jack for something other than tire changing, half had not chocked a wheel, and half had not properly set the parking brake. ODI notes that since the front wheels are drive wheels (with an open center differential) the Park gear cannot provide vehicle stability (longitudinally) when a front wheel is raised. All NHTSA complaints and most of the complaints to Ford involved failures while a front wheel was raised.In response to ODI's inquiry, Ford conducted testing on a 2004 Freestar. Ford's tests showed that when a front tire was raised the service jack held without failing under various scenarios except when a rocking force was applied and the parking brake was not properly set. Based on its testing and its analysis of field data, Ford concluded that the type of jack failure evidenced in this investigation (bending at mid-point) was likely caused by vehicle movement due to an improperly secured vehicle, or other misuse of the jack. Ford notes that rates in this investigation were similar to those in another investigation (EA91-049) which ODI closed. ODI also analyzed jack data for MY 2003 and newer vehicles to compare to the SV population. To assist with this analysis, ODI requested data from the jack manufacturer (actually its successor company) who provided limited data but did identify other models using the same design jack. ODI was unable to identify a significant difference in the incidence of jack failures (including those involving bending failures) between the SVs, other vehicles which used the same jack, or other vehicles where the jack type was unknown or different.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, investigation PE11-033 is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist and ODI reservesRead more

PE, Closed , Model Year: 2004

Engine Stalling

The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on w... Read more

EA, Closed , Model Year: 2004

Transmission Torque Converter Failure

On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufa... ctured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.Read more

PE, Closed , Model Year: 2004

TORQUE CONVERTER OUTPUT SHAFT FAILURE

ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRA... Read more

DP, Closed , Model Year: 2004

Engine stalling

On May 6, 2009, NHTSA received a request for a hearing through Title 49 of the United States Code, Chapter 301, Motor Vehicle Safety, Part 557. the request was in reference to vehicle owner complaint, 10266067, filed with NHTSA on April 20, 2009, which described a problem with engine stall in a mode... Read more

FORD FREESTAR - All Years Overview

Complete safety history for the FORD FREESTAR across all model years (2004, 2007).

14 Total Recalls

3,223 Total Complaints

8 Investigations

44 Reported Crashes

26 Reported Fires

1 Reported Deaths

FORD FREESTAR - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2007	2	77	View
2006	3	453	View
2005	4	1,093	View
2004 (current)	5	1,600

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-450 SD	692	624	View
F-150	692	46,142	View
F-250 SD	638	3,635	View
EXPLORER	624	42,549	View
F-550 SD	578	603	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2004 FORD FREESTAR

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 2004 FORD FREESTAR

Most Affected Components

NHTSA Safety Investigations, FORD FREESTAR

FORD FREESTAR - All Years Overview

FORD FREESTAR - Year by Year

Other FORD Models