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:
2 / 2
Injuries / Deaths:
2 / 0
Average Mileage:
98,177 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 engine problems

engine problem

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2004 Ford Freestar Owner Comments (Page 3 of 3)

« Read the previous 20 complaints

problem #13

Feb 122013

Freestar 6-cyl

  • 86,000 miles


I have had this van 1 month and paid $8000, its my first car payment,86,000 miles and I am losing power and the water light is coming on the van is jerking when driving this, ,I want to learn about the lemon law in Michigan.

- Highland, MI, USA

problem #12

Feb 062013


  • 39,000 miles
Basically, when it's wet outside the car dies after starting. There will be a loud screeching sound coming from under the hood and then it will just stutter and stall out. It will start right back up but then it will die again. This will even happen while driving down the road. It seems to only happen when it's wet outside so far but we have no idea what it causing it and the dealer is no help at all.

- Munford, TN, USA

problem #11

Feb 192009


  • 65,000 miles
The contact owns a 2004 Ford Freestar. The contact stated that while driving 55 mph, the vehicle stalled without warning. The vehicle was taken to the dealer for inspection and they stated that the computer module and the coil pack needed to be replaced. The vehicle was repaired but the failure recurred four more times. The manufacturer was notified but provided no assistance. The failure mileage was 65,000.

- Buffalo, NY, USA

problem #10

Dec 172012

Freestar 6-cyl

  • 117,000 miles


The PCM internal computer is crashed and cause the veh to run poorly and not start, drained batter, etc - this is an issue with a lot of 2004 Freestars as I read online and was told to submit the info so that maybe they will do a recall and get this fixed. Thank god it did not happen while driving.

- Houston, TX, USA

problem #9

Mar 012012


  • 115,000 miles
The contact owns a 2004 Ford Freestar. The contact stated while traveling 15 mph the vehicle suddenly stalled. As a result the vehicle crashed into the vehicle directly in front of it. A passenger in the front vehicle sustained unknown injuries. The vehicle was towed to a private mechanic where the failure could not be replicated. The vehicle was not repaired. The manufacturer was not contacted about the issue. The failure and current mileage was 115,000.

- Benton, IL, USA

problem #8

Oct 102012

Freestar 6-cyl

  • 87,000 miles
The car was driving fine all of a sudden the Freestar lost power, I was doing T most 40 mph because it was during rush hour on the I15 hwy by hesperia everything was fine and all of a sudden my car lost power and began to feel like it was loosing power and then I saw it go from forty to slower mpg and I had my foot on the accelerator I immediately pulled over as soon as I could and there was smoke and then there was fire my 1car was burnt a total loss my daughter and I barely escaped with our lives minutes before the van exploded someone had put us in her car and drove us forward saving our lives when the fire department arrived I walked back to my car and the fire had expanded far past where me and my daughter were standing. My daughter is still traumatized by the experience and so am I. we would of been severely burnt or died when the car exploded and everything caught on fire past the spot my daughter and I were standing the firemen could not believe that the fire had been so extensive. We lost everything my daughter loved, all her most precious material things we went from driving on a happy trip to the realization we could of died by the fire. If the passerby would not had put us in her car and drove us to safety.

- Bell, CA, USA

problem #7

May 012009

Freestar 6-cyl

  • 89,000 miles


The vehicle loose power will stall with engine running other times engine would stall 2-4 seconds the jump back on happen alot when plgs wires are fine it rains, get engine light also. Resets, but will resume on the next start with emission codes and PCM errors.

- Cleveland, OH, USA

problem #6

Sep 202012


  • 165,000 miles
At 147000 miles, I needed a complete transmission rebuild. This cost me $2800 due to the fact that there were additional parts not common to a standard rebuild. This was Sept. 2011. In January, I am able to note online that there is a torque converter recall for this model. I call Ford, I'm told there is nothing they can do until the recall is officially released in the 2nd quarter. Wait until 2nd quarter, no notice in the mail. I call Ford in August and tell them this, I am told that Ford will fix the car, it will take approx. 4 days and that no rental car is available during this period. If I suffer a total loss, maybe. Basically, I have to be stranded on the side of the road with my two young children before I can get any help with their issue. After rebuild, I start having issues with cylinder 3 misfire. I replace all plugs and wires, still a cylinder 3 misfire as well as overheating and egr valve. Replace egr valve, complete radiator change, coil pack, still issues with misfiring and overheating. I understand that this could be a computer issue, however Ford fails to realize this and therefore will not issue a recall. Not that would help since if they took it into the shop to fix it, I would not be able to get to work in the interim.

- Chester, MD, USA

problem #5

Sep 082012

Freestar 6-cyl

  • 107,812 miles
Van won't start thought it was fuel pump had it towed & replaced cost $500 van starts then shuts off mechanic said PCM malfunction dealer should fix it! help Ford stand by there vehicle! complain.

- Sewell, NJ, USA

problem #4

Jan 152012


  • 100,000 miles
The contact owns a 2004 Ford Freestar. The contact stated that while driving approximately 25 mph, the vehicle suddenly stalled. The contact was able to restart the vehicle but it continued to stall. The failure occurred four different times after rainy weather. The vehicle was taken to an independent mechanic for a diagnostic test. The mechanic was unable to diagnose the failure. The vehicle was not repaired. The approximate failure mileage was 100,000.

- Beaumont, TX, USA

problem #3

Jul 022012

Freestar 6-cyl

  • 81,000 miles


Had powertrain symptoms related to Ford tsb 06-14-10, for engine/transmission driveablity. Had vehicle towed because I had no reverse & forward engagement, and high idle in neutral. Ford dealer, fixed transaxle per safety recall 11S25, and tsb 06-14-10, for water entering the PCM. Dealer returned our vehicle on July 10th, everything appeared okay. One July 11th, the van began have shift issues, and then stall going down the road at 20-25mph. If the PCM is damaged from water, then why don't they require replacement in the tsb. This is a serious safety issued, especially at 70mph on a freeway. This tsb should be reconsidered as a safety recall. How many people should be injured or killed due to this condition? one is to many!

- Fowlerville, MI, USA

problem #2

Jun 172012

Freestar 6-cyl

  • 42,442 miles
Upon exiting the freeway onto secondary street the vehicle stalled out completely. We lost all driving function, power steering etc in an instant. Luckily it was later in the evening and not much traffic was behind us as this road is typically very congested. We were able to glide into a turn lane and off of the main road. The vehicle would not start and had to be towed. Local Ford dealer concluded the PCM shorted out and there was a blown ignition coil. We had car towed for second opinion as we could not believe that at 40,000 miles the entire computer that controls the engine would short for no apparent reason. Our regular auto shop agreed that the PCM had shorted causing ignition coil to fail and both had to be replaced resulting in $1200 in fees/services and a week without our vehicle since the part (according to the service shop) should never go bad and they don't keep them in stock. We feel as if Ford should be held responsible for their faulty manufacturing as we did nothing to aid in the failing of this part and minimal mileage/ wear and tear has occurred to the vehicle. We were merely a family driving home (with two toddlers) from a father's day dinner who ended up at significant safety risk when our van just stopped moving, thank goodness for the slow traffic flow that evening!

- Virginia Beach, VA, USA

problem #1

Jun 042012

Freestar 6-cyl

  • Automatic transmission
  • 78,000 miles
I left work, got 3 parking spots away, lost steering, brakes and gas. Engine was still running. Transaxle light came on, shut off van, tried again and it drove maybe a few feet and it was as if it was in neutral. Engine light, battery light and oil light came on. Shut it down tried again, drove about 10 feet and it died. Had it towed to vip who had no answers, towed to Ford who said it there was water in the PCM. They dried it out and said give it a go. Got it home drove it one day and the next(after raining) it would not move out of driveway. It would go into gear but hitting the gas was again like in neutral. It would move maybe a few inches and then no longer. The engine light came back on and the van bucked some. Towed to Ford again and they said it is defiantly water getting in the PCM. I have been searching online and I see many people complaining about this issue. I am worried because there is another recall coming in a month or so for the torque converter and I have 2 small children that rely on that van. I can't trade it in cause they are only will to give us $1000 when we owe 6. we are without vehicle again, with my husband and I having jobs and two kids. I feel unsafe in my van, even if we are to get it fixed, we have to hope the torque converter does not go while we are driving before the recall.

- Sanford , ME, USA

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