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 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
84,083 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 cooling system problems

cooling system problem

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2004 Ford Freestar Owner Comments

problem #3

Jun 012010

Freestar 6-cyl

  • 66,250 miles


The manifold and tube assy which runs from my condenser to the compressor blew out while my family was driving down the highway. Prior to this in may of 2010, after the birth of my 3rd child, I was taking him to his 2 week checkup and it was pouring down rain and the windows were fogging up so bad that I had to use a paper towel to wipe the windows so that I could see out them. The A/C system has not worked properly since I have purchased my Freestar in Feb of 2010. There was a ticking noise before the hose blew and before we could figure out where it was coming from the hose and all our freon was a cloud of white behind us. We have taken our van to one shop which said that the condenser and evaporator was bad then took it for a second opinion where they replaced the manifold and tube assy and recharged the system. They found that the compressor was only putting out 100 lbs of pressure but should be putting out 250 lbs. They said it was safe to use (but the air would only be cool while highway driving not while stopped) until they were to replace the compressor in 3 days, and that with only 100 lbs of pressure the hose would not blow again. After less than 24 hours and maybe 3 hours of actual A/C time the hose blew again and out came all the freon. When we took the van back they were at a loss of why. I have now spent over 300 dollars that was useless and we are back at square one because noone knows why this is happening. I have read other complaints by Freestar owners who have had the same problems. Before this is over I expect to spend over 1700 dollars which I don't have for a problem it seems many others have.

- Eddyville, KY, USA

problem #2

Feb 262008


  • 102,000 miles
Bought van in June 2007 nothing but problems since. Replaced battery within 2 months of purchase. Replace O2 sensors 3 times and need done again. Replaced transmission, radiator, egr valve, brakes 4 times, tie rod 2 times, calibers 2 times, rotors 3 times, fuel line, you name it, we have had to fix it. Nothing but problems. We have spent close to 8K since Feb 2008 on this vehicle and we can not get Ford to help us at all. Now the axles need replaced as well as sensors again. The dvd player quit working after 4 months, driver side heated seats quit working after 4 months. Back passenger door sometimes won't open or unlock and sometimes it won't close when you try to close it. This vehicle has put my family in serious harm and we almost got into major accident do to most of the issues ie transmission stalled on interstate and had no warning at all. Worst vehicle of all times. I can not trade in becasue I owe over 11K on this piece of crap. Ford needs to refund me all of my money and suffering as well. I have thought about suing them for damages and selling this crap to us especially with 3 small children and having to travel to see family due to husband being a marine and always being deployed. Almost missed seeing my grandpa for the last time before he did back in Sept because of the transmission. This vehicle needs to be off of the roads forever. All of them. Everyone that we know that has these vehicles have the same problems as us.

- Ft. Meade, MD, USA

problem #1

Jun 032008


  • 84,000 miles
I have a 2004 Ford Freestar and this summer my air conditioner stopped working. I called Ford Motor Company and told them that I had the car for less than 3 years and needed their assistance in order to get my car repaired. They declined to give me any assistance.

- Raleigh, NC, USA

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