Notes: The Freestar was introduced in 2004, but it was essentially just a rebranded Windstar. While there was a redesign of the interior and exterior, the Freestar still inherited some of the design flaws of its predecessor.


hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
103,969 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford Freestar body / paint problems

body / paint problem

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2004 Ford Freestar Owner Comments (Page 3 of 3)

« Read the previous 20 complaints

problem #14

May 192012

Freestar 6-cyl

  • 71,065 miles


While turning a corner we heard a loud noise coming from the left rear tire. After getting home we pulled the left rear tire off to inspect the brakes, which were fine. We did notice that the wheel well was rusting out around the third row seat latch. The latch was loose and upon further inspection did not lock the third row seat into place. When carrying passengers in the back seat the latch is pushed out far enough that it actually rubs on the rear tire, which could result in tire failure.

- Spirit Lake, IA, USA

problem #13

May 122012


  • 91,000 miles
3rd row bench seat, drivers side U type bolt bracket( the inside piece that the rear seat locks into)...competely rusted through and partialy fell onto the tire and brake assembly. The passengers side in also cracked and brittle. The van still runs fine but we cannot use the 3rd row seat. Our childeren were sitting on it when it finally broke and fell on the wheel. It made a hell of a noise. We were able to get stopped without much of a problem.

- Desmoines, IA, USA

problem #12

May 062012


  • 96,400 miles
The contact owns a 2004 Ford Freestar. The contact stated that the rear driver side of the vehicle was rusted. The rear driver side wheel well was rusted and reached the fuel filler pipe. The contact also stated that the rear driver side seat was also rusted and would not lock in place. The vehicle was not taken to the dealer for inspection or repairs. The failure and the current mileages were 96,400.

- Jefferson City, MO, USA

problem #11

Mar 252012

Freestar 6-cyl

  • 75,600 miles


Rear 3rd row seat latch is completely rusted through making the rear seat completely unsafe and unusable. Could cause serious injuries in a accident if rust goes undetected, vehicle is kept in garages and well maintained. Updated 05/31/12

- Mahwah, NJ, USA

problem #10

Apr 012011

Freestar 6-cyl

  • 115,000 miles
Left rear seat no longer latches making it unsafe. The seat no longer latches because latch that was fastened to the left rear wheel well has rusted completely off the wheel well.

- Hudsonville, MI, USA

problem #9

Mar 052012

Freestar 6-cyl

  • 128,641 miles
Noticed inside carpet was wet on the rear left side, removed the inside rear wheel panel and found the third row seat latch had completely rusted through to the outside of the car allowing water to enter the cab space and now the third row seat is unsafe due to the seat not being able to latch.

- Brunswick , OH, USA

problem #8

Oct 202011

Freestar 6-cyl

  • 72,200 miles


When making a right turn with a full load (my wife, 2 kids, my parents and I) a vibration occurred in the left rear wheel well. I couldn't find the problem myself so I took the van to the Ford dealer the next day and they diagnosed that there was rusting in the left rear wheel well which caused friction against the tire when turning right with a full load. The service manager at the Ford dealer recommended that I do not drive the vehicle and replace the vehicle as it was too dangerous to drive. I was not planning to sell the van for scrap after 5.5 years and I couldn't morally sell a car that I wouldn't feel safe driving with my own family. I took the van to a body shop and they recommended a specialty shop. The specialty shop identified the problem as a panel that was not sealed well which caused premature rusting. They were able to cut out the area and replace that part of the wheel well. I see this as a very serious safety hazard that I hope others don't encounter. If I had not taken care of this problem immediately the tire could have been damaged while turning right with a full load and caused a serious rollover accident. I was not happy with the Ford service manager's advice of buying a new car versus helping me fix the problem. I felt it was important to file a safety complaint as the result of this type of premature wear on a vehicle could turn out to be tragic for someone.

- Fairlawn , OH, USA

problem #7

Dec 262011


  • 137,000 miles
TL - the contact owns a 2004 Ford Freestar. The contact stated that the hook that held the rear driver side convertible bench seat in place was completely corroded. The contact mentioned that the damage was so severe that it rusted through the body of the vehicle. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was no longer under warranty. The vehicle was not repaired. The failure and the current mileage was 137,000. Kmj

- Wadsworth , OH, USA

problem #6

Dec 142011

Freestar 6-cyl

  • miles
Paint peeling off roof and hood, looks like they used two different primers.

- Port Alberni Bc Canada, WA, USA

problem #5

Dec 042011

Freestar 6-cyl

  • 92,300 miles
Upon opening the folding third row seat, the bottom latch failed to engage with the seat. Further inspection showed that the entire latch panel had rusted away from the body of the car and was sitting in the wheel well. There is now a hole in the side of the van and the third row seat is unusable. At 7 years old, this level of rust is very premature.

- Quincy, IL, USA

problem #4

Nov 172011

Freestar 6-cyl

  • Automatic transmission
  • 92,300 miles


The contact owns a 2004 Ford Freestar. While the vehicle was parked the contact lowered the third row seating to the floor when he noticed the safety latch attached to the rear wheel wells was corroded from the inside out and were fractured. The contact stated the third row seat could not be used because it would be unsafe in the event of a rear end collision. The dealer was made aware of the failure and refused to inspect the vehicle. The vehicle was not repaired. The approximate failure mileage was 92,300. Updated 12/20/11 updated 01/19/12

- Niantic, CT, USA

problem #3

Aug 022011

Freestar 6-cyl

  • 46,000 miles
Drivers side front door will not close. Exercised all locks open and closed multiple times, but door will not latch closed. Major safety issue.

- Severna Park, MD, USA

problem #2

Jun 162009


  • 68,596 miles
The paint on my 2004 Ford Freestar van is bubbling and peeling off of the roof of the vehicle.

- Eaton, CO, USA

problem #1

Mar 282004


  • 750 miles
Plastic molding along the running boards broke off. As a result, the sliding door malfunctioned, locking occupants inside vehicle.

- Vermilion, OH, USA

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