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.


really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
90,148 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 electrical problems

electrical problem

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2004 Ford Freestar Owner Comments (Page 2 of 6)

« Read the previous 20 complaints

problem #84

Jun 112014


  • miles


The contact owns a 2004 Ford Freestar. The contact stated while driving 70 mph, the check engine and trans axle lights illuminated on the instrument panel. Immediately after, the vehicle stalled and was not able to be restarted. The vehicle was towed to an independent mechanic. The technician was unable to diagnose the failure. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was unknown.

- Eight Mile , AL, USA

problem #83

May 052014


  • 180,000 miles
In good weather without warning the engine stalled in traffic. Restarted, but the engine ran extremely rough. Also the transmission would not go into reverse. Managed to get to a independent service shop. There the technician found water in the PCM. Dried out PCM and car ran fine. Then the transmission light came on. Now they found water in the transmission connector. Two weeks later the car would often not start, and when it did the transmission would not shift out of first gear. On our third visit they replaced the throttle position sensor (tps). One week later same symptoms, this time tps and mass airflow sensors have failed. The problems are all related to the wet PCM! recall this car, now!!!!!

- South Lyon, MI, USA

problem #82

May 142014

Freestar 6-cyl

  • 165,000 miles
RPM's surge, loss of power while driving, already had recalls done and still having problems, trans axle light comes on when doing highway speeds., I think the recall needs to be on the electrical system and where the main computer is located. The main computer is right beneath the awning for the wiper assembly...lots of potential water damage and many unhappy customers. This is supposed to be a family vehicle and it is more like driving a ticking time bomb. I would hate to be on the highway and the vehicle just suddenly stop. Not good Ford!!! not good!

- Beltsville, MD, USA

problem #81

Jan 032005

Freestar 6-cyl

  • 50,000 miles


Problems with engine since 2005 with jerking, sputtering, engine lockup. Transmission locks and jerks, airconditioner stopped cooling and won't hold freon. Electrical issues also......has a mind of its own! several trip to the Ford dealership, was told "could not diagnose, bring it back if it does it again, we can't find anything wrong with it". the issues are sporadic. Drives fine one minute, next thing you know you are stalled on busy hwy. Not enough space to list "expensive" problems. Extended warranty? that's a joke, waste of $. scariest issue is when it locked up while driving. Lost complete control of steering, acceleration, etc. Was stranded in middle of road. Have disability, very scary & frustrating especially since my husband bought it only a year old so kids and I would have a "safe" vehicle. Did not take back to dealership since they'd probably say " can't diagnose". purchased a rebuilt engine had small town mechanic put it in. Problems still going on. Since there are still so many problems with engine, transmission, electrical, and no air conditioning, I'm afraid to drive it more than 5 miles. It is a very expensive lawn ornament. Fyi, my husband had just had to replace the engine in his Ford vehicle a month before mine went out, had to sell his vacation time for 2 years in a row just to keep those Ford running for our family...he's a public safety officer. Ford sold be ashamed. (dates are approximate, paperwork packed up from a move....sorry:-) )

- Wetumpka, AL, USA

problem #80

Nov 012013

Freestar 6-cyl

  • 90,000 miles
In November of 2013, our 2004 Ford Freestar quit working. Yes, we had the torque converter recalled and put on back when they had that recall. November was the first time we had this happen to our car. It was raining, and our car would not go into gear, it quit working. What made this bad is that it was on the freeway! my husband put it into neutral, but we still did not have steering capabilities and managed to get us over to the shoulder. We had to be towed to a dealership. The dealership then stated that many people were having the same issue with the electronics getting wet, so he dried it, then let it set for a couple days and caulked it. We thought that would end those problems. Not. (note: This had cost us 450.00) then less than 2 months, the same exact thing happens, only this time we are stuck in a shopping center and could not get our car into gear again. We took it back to the dealership to which they replied that we needed a new electric module. How much" $1500!!! in less than 2 months, we spent almost 2,000.00! this was done in February. Here it is now April and guess what" the same exact problem is taking place again!! we are not alone, there are many people facing the same problems we have had, look around at the boards online and you will see that everyone has the same issues!! some investigations need to be opened or reopened as this is not resolved and lawsuits will be filed if someone gets hurt.

- Gig Harbor, WA, USA

problem #79

Nov 152012

Freestar 6-cyl

  • 127,761 miles
PCM module got water in it. Had it replaced by dealer, charged $765.02. Now 14 months later car back in dealer for same issue and their one year service warranty has expired. About ready to spend another $800 to fix. Obviously a design flaw, no question about it.

- University Place, WA, USA

problem #78

Nov 162013

Freestar 6-cyl

  • 127,102 miles


Driving South on I 75, returning from a week's vacation, in medium Saturday traffic the car started to act up. Lights, warning lights, gauges, even the temperature and compass started flashing and going on and off. There was an exit a mile ahead when the engine died, right in front of a semi. I had to swerve to the side of the road to narrowly avoid an accident. The car would not start after that. I had to arrange a tow and was left stranded for five days. The Ford dealer up North could not get the part for three weeks. Now it's at a Ford dealer here, by detroit, for over a week. They said it will cost over one thousand dollars to replace the PCM. Looking on line I see all the complaints and repairs reported about this car, and you are doing nothing"? after seeing the PCM and the repairs to fix the problem you have to wonder why the brain of the car is in a spot where it can get wet, and why there are holes in the top to let water in? how many problems, accidents, or deaths do there have to be to start a recall???"

- Warren, MI, USA

problem #77

Nov 112013


  • 100,000 miles
Almost every time we start the van, the odometer has all dashes through the reading and the speedometer will not work. After restarting the van sometimes several times it fixes itself. The problem has been getting progressively worse. I have been seeing a lot of information in forums about water getting on the PCM due to a manufacture error, but have not seen a recall for the issue. After removal of the air damn to do minor maintenance to the vehicle water is able to seep pass a misplaced spot weld and drip on top of the PCM unit. Damage to the unit causes several issues including the problem I am facing with my van.

- Bloomfield, IA, USA

problem #76

Aug 182013

Freestar 6-cyl

  • 120,000 miles
Was driving with cruise control and vehicle started lurching while driving. While in park rpms go up and down. Feel like vehicle is struggling. Had recall issue taken care of last month. Doors also lock when they want to and sometimes windows don't work. Always happens after rain.

- Newberry, FL, USA

problem #75

Aug 162010

Freestar 6-cyl

  • 80,000 miles
Stop running sometime would start, then wouldn't start, took to a shop they said look at it been submerged or under water, at eclt plug where, wet with water, said it wood need new wiring harness, possible computer cost of $1200-1500 part and then there in kenai to fixer if I want to do this...I bought this used here came up from the South, Arizona, done car fax all good.

- Kenai, AK, USA

problem #74

May 212013

Freestar 6-cyl

  • miles


While my husband was on his way home from work he came upon a red light. When the light turned green again he attempted to accelerate but the van would not move. He turned the ignition off and then on again and the van still would not move. All of this occurred without any warning, no lights flashing or any kind of unusual sounds. After having it towed to the dealer we purchased the vehicle from we were told that the van had an electrical problem that needed to be handled at the Ford dealer. Now what I have been told is that the electronic computer module was the problem and needed to be replaced. This repair cost us $1200 dollars after having the van for just under five months. We are paying close to $13,000 for this van and were not able to drive it safely for at least six months without repair. Someone should protect the consumer a little better than they are. This is devastating for my family considering this is our first vehicle and we are still inexperienced with the was dealers prey on their potential customers, Ford should be ashamed of how they treat the people who are the one's who keep them in business. I think people should take a stand to refrain from purchasing Ford vehicles until they take consumer safety seriously. There should also be a law which states that any used car dealer disclose recall information to the potential buyer before a contract is entered into. The type of problem that we have could have ended in serious injury or death had this happened on the highway.

- Baltimore, MD, USA

problem #73

Jun 142013

Freestar 6-cyl

  • 105,000 miles
Recently had the transmission torque converter changed under recall. Today it was running rough, and would stall out. It was a dangerous situation as I was in heavy traffic at the time. It seems that this problem. Has happened to many other owners of the same car.

- Plattsburgh, NY, USA

problem #72

May 102011


  • miles
The contact owns a 2004 Ford Freestar. The contact stated that the air conditioning would not cool the inside of the vehicle. The contact took the vehicle to the dealer and the dealer added freon, but it did not correct the problem. The dealer also stated that the compressor was operating properly. The contact stated that the air conditioning did not seem to truly start working until the vehicle speed was at 40 mph and above. The vehicle was not further repaired.the VIN was not available. The failure mileage was unknown, but the current mileage was 140,000.

- Atlanta, GA, USA

problem #71

Apr 112013

Freestar 6-cyl

  • 98,000 miles
While driving my son to school, vehicle stalled at 45 mph and engine died. Got vehicle started again, died again, managed to get vehicle back home. This issue has been happening intermittently ever since with no warning engine will die while driving vehicle. I have been advised by a mechanic that this is due to the PCM getting wet repeatedly. After researching issue on-line, this appears to be a design issue that Ford should address immediately before it results in a fatality.

- Mundelein, IL, USA

problem #70

May 172013

Freestar 6-cyl

  • 62,000 miles
Hi I am [xxx] was out Friday at about 5.30 when my 2004 free star van started acting up it cut off 3 time right at a light this is [xxx] just got the van 6 mos ago for 9,300 at a Ford dealer in lexington nc.maybe going to quit buying Ford ect car van what ever had to call my dad to come help me the van would not run or start because of the PCM box had water on in Ford don't want to do a [xxx] thing but make me pay more money just got the van for 9,300 now got to pay 1,2600 at a Ford dealer in whiteville nc I don't have the money but my dad and bother is going to pay for it to get fix this time maybe sale the [xxx] 2004 free star van soon I don't want to but if I don't sale it may happen again to me.Ford need to recall this [xxx]now before someone get killed I when down the road and could not control my van and now I have brakes went out to "???"look Ford send me my money back 1,12200 to me in whiteville nc 2872 to [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Whiteville , NC, USA

problem #69

May 312012

Freestar 6-cyl

  • 146,000 miles
My van would not go in reverse, when it finally did it kept dying. Took to Ford dealership the problem was the computer brain cost 1100. 2days later the exact same thing. The problem is sudden leaving U stranded with no warnings.

- Sheridan, IN, USA

problem #68

Apr 292013

Freestar 6-cyl

  • 187,000 miles
While driving to take my husband to work in the rain my wipers began to slowly lose power and slow down, then my radio shut off, my head lights began to turn off then off then they loss power, finally my dashboard began to have the oil light and ABS light and emergency brake light come on, then the battery light turned on I took it to a mechanic and they said it something electric and maybe the PCM I contacted Ford and they said they have no recall for that and can't help me unless I want to pay out of pocket. My mechanic also said they have seen many other Ford Freestars with this problem as the van was made that the PCM is locatedwhere water comes in with rain and ruins them. We are afraid that an electric problem may cause a misfire and even a fire to the vehicle.this is my only vehicle I have and strongly depend on it since I am 6.5 months pregnant and have a 2 year old and am afraid of being stranded somewhere with him. Had I known that this car was so unreliable and irresponsible for their mistakes and un willing to help, I would of purchased a foreign car with better warranty and quality as well as better service.

- Pleasantville, NJ, USA

problem #67

Apr 122013

Freestar 6-cyl

  • 166,000 miles
As I see this is a very common problem with all model year Freestar vans. Water leaks onto the PCM and shorts out then your van won't run or if it does not very well. Mine won't start and gives all kinds of random mil codes. Was diagnosed with water in PCM. Plain and simple Ford needs to issue a recall for this because all the vans have it or will get it.

- Ypsilanti, MI, USA

problem #66

Sep 032012

Freestar 6-cyl

  • 100,000 miles
Had the recall work done on the torque converter end of August beginning of September 2012, upon return of vehicle have had nothing but problems. Last Thursday April 4 the vehicle suddenly lost power while going through an intersection. Friday did the same thing 3 times in less than 20 minutes of driving. Replaced alternator, belt tensioner and belt. Mechanic asked what it did, then said it might be the torque converter. He checked power steering, and water pump they are fine. Not sure how a part less than year old could go bad. When my vehicle went in for recall was perfectly fine, since it's return is has been running horrible and nothing seems to really fix it.

- Aurora, IL, USA

problem #65

May 082007

Freestar 6-cyl

  • miles
The latch on the rear of the van has rusted closed on three separate occassions. It is presently rusted shut and the back hatch doesnt open as a result. There is a recall on the third row seat due to water leakage from the rear tire well. This has to be related as the carpet throughout the van gets wet. Even the front drivers seat where it attaches to the floor is soaked, posibly leaking from front tire well.and all the way down the interior of the car to the third row. There is also a short in the dash lights due to water leaking into the dash area. The car radio stays on when it feel like it and you have to hit the drivers window button for the radio to shut off otherwise it drains the battery and the car will not start. The car was at the electrical shop a year ago and could not find the problem.

- Wyandotte, MI, USA

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