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.


definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
27,247 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 brakes problems

brakes problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Ford Freestar:

Unsubscribe any time. We don't sell/share your email.

2004 Ford Freestar Owner Comments

problem #8

Jun 172007

Freestar 6-cyl

  • Automatic transmission
  • 36,600 miles


While on vacation, grinding noise was heard from the left rear brakes, brought van to a local Ford dealer. It was determined that the inner brake pads wore uneven and were metal to metal on the rotors. New pads were installed and rotors turned at a cost of $215 and loss of a vacation day with family.

- Beacon Falls, CT, USA

problem #7

Apr 112007

Freestar 6-cyl

  • Automatic transmission
  • 22,651 miles
On 4/11/07 Ford service department. Informed me the rear brakes & rotors on the 04 Freestar were shot and needed immediate replacement at a cost of $575.I thought they were lying to me because I had more than 20 different cars, trucks, & vans, but never had factory installed brake pads wear out at 20000 miles, and especially rotor damage so bad that they had to be replaced. Also there was no warning signs like a grinding noise or a pulsating brake pedal. Nothing. So I mentioned the 3/36 bumper 2 bumper warranty, and the 6/75000 esp plus deluxe extended warranty w/$0 deductible, and I was told this was a wear item, and was not covered. They said I probably rode the brake pedal or drove with the parking brake on. I didn't drive with 2 feet and never used the parking brake. I asked how long were the brakes designed to last under normal use, .they didn't know. So I left the dealer, and went to an independant ex Ford mechanic, who determined to find a frozen caliper or something else defective.what we found was not what I was expecting.the calipers were not frozen, and the pads were not completely worn down although the outer pads were twice as worn as the inner pads, there was no metal to metal contact(rivets or pad backing).it seems that the metallic or semi-metallic pads themselves would rust a bit and since the front brakes do most of the stopping, T he rust on the rear pads never completely wore off each day and the pads and rotors never heated up enough to built up the glaze like the front the rotors were gouged by the rust build up on the pads. When examined closely, the deep gouges on the rotors lined up with the rust build up on the pads.

- Islip Terrace, NY, USA

problem #6

Feb 182007

Freestar 6-cyl

  • Automatic transmission
  • 40,966 miles
The contact owns a 2004 Ford Freestar. While driving at 5 mph the contact heard a grinding noise in the rear of the vehicle when ever the brake were depressed. The mechanic stated that the grinding noise was due to the rear brakes. The mechanic replaced the rear brake pads, rotors, and calipers. There have not been any occurrences since the repair. The failure and current mileage was 40,000. Updated 05/04/07.

- Schertz, TX, USA

problem #5

Jun 062006

Freestar 6-cyl

  • Automatic transmission
  • 45,000 miles


Started to notice grinding noises and excessive wear to rear pads and rotors. Took car into local dealer for inspection. Was told that yes, the rear needed new pads and rotors and since it was normal wear (approximately. 40K miles) it was not covered under vehicle extended warranty. Took vehicle to ind. Repair shop for repair. Front brakes have been trouble free so far.

- Mckinney, TX, USA

problem #4

Jun 182006

Freestar 6-cyl

  • Automatic transmission
  • 31,000 miles
: the contact stated there was a popping and grinding noise heard coming from the front passenger side area. Prior to taking a trip, the dealership replaced the brake pads on the front passenger side. When the contact returned from the trip, there was roaring noise coming from the rear of the vehicle. The dealership determined the rear brakes needed shoes and rotors.

- Louisville, KY, USA

problem #3

Jun 072005

Freestar 6-cyl

  • Automatic transmission
  • 40,106 miles
Grinding noise in rear pass side wheel. Caliper failed, caused the pad to slip and ate through the rotor causing the wheel to lock up completely. Took vehicle to Ford dealer, they advised the whole brake system needed to be replaced, which we did. Caliper, rotor, and pad replaced on rear pass side brake system, and pad replaced on rear driver's side.

- Mechanicsville, MD, USA

problem #2

Jul 162004

Freestar 39-cyl

  • Automatic transmission
  • 1,650 miles
My left inner brake pad fell apart and almost caused an accident.. my left brake was locked up on inner side. Dealer put new pads and fixed rotor on my 2004 Freestar. Also excessive front brake noise and squeal.

- Mesa, AZ, USA

problem #1

Jul 192004

Freestar 6-cyl

  • Automatic transmission
  • miles
The consumer tapped the brake to stop and the left rear brake locked up. It was later detrermined that the left inner pad had worn unevenly.

- Mesa, AZ, USA

Not what you are looking for?