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 / 3
Injuries / Deaths:
0 / 0
Average Mileage:
68,927 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 2 of 2)

« Read the previous 20 complaints

problem #14

Dec 012010


  • 65,000 miles


2004 Ford Freestar engine control module computer die @ about 80000 miles tranmission fail at about 65000 miles defective oe conformal coating is removed from the entire ECM board including underneath chips and replaced with upgraded conformal coating; corrects an oe design flaw and ensure chips will not lift from the board causing the unit to fail.

- Lawrence, MA, USA

problem #13

Sep 012009


  • 79,000 miles
The contact owns a 2004 Ford Freestar. The vehicle stalled intermittently while driving approximately 20 mph. The check engine light illuminated prior to the failure. The vehicle was taken to a local mechanic several times. The mechanic replaced the gas filter, and cam sensor twice, but failure continued to occur. The vehicle was taken to the dealer who stated that the failure was caused by the power control module. The estimated repair cost was $940. Report 1898911628 was filed with the manufacturer. The manufacturer stated that they have not received any related complaints. The failure mileage was 79,000 and the current mileage was 80,800.

- Missouri City , TX, USA

problem #12

May 132010

Freestar 6-cyl

  • 126,665 miles
My 2004 Freestar suddenly quit running last week. There was very little forward power and no reverse power. It also began sitting and sputtering terribly and would not start. I made it to the edge of traffic. It had been wet and rainy all week. Now that the weather is dry the van starts. This is an ongoing issue. I have already replaced the transmission once.

- Nowalk, WI, USA

problem #11

Feb 262010

Freestar 6-cyl

  • 65,000 miles


I noticed the NHTSA may have opened a probe on the 2004 Ford Freestar transmission issue. The transmission has failed twice at 65,000 miles, once with my wife driving alone at night at highway speed, and the second time with my 17 year old daughter driving at night with friends. Both times created extremely dangerous situations to the occupants and fellow drivers on the road around them. The first the transmission failed at 65 mph, lost power completely. At the time I had the van towed to lindsay Ford in wheaton, md and the torque converter replaced for $2,200. Two months later the incident occurred again with my daughter driving and we had it towed to the dealer again and they "could not duplicate the problem and saw no codes"- paid another $300 for "camshaft sensor replacement" this is an extremely dangerous situation. I have heard this issue has occurred repeatedly and numerous times.

- Bethesda, MD, USA

problem #10

Jan 012010


  • 75,000 miles
Driving down a small hill, came to a complete stop. Made a right hand turn started to accelerate and lost all power. Drifted to the left hand side off the road and came to a complete stop in the left drive lane of the highway. Very dangerous spot to be in.

- Glen Burnie, MD, USA

problem #9

Jan 012009


  • 90,000 miles
The contact owns a 2004 Ford Freestar. While driving 45 mph, the front driver's side tire shook heavily. The contact also heard a very loud noise coming from the engine. She took the vehicle to a mechanic and was informed that a new hub assembly and wheel bearings were needed. Through online research, the contact discovered NHTSA campaign id number 04V446000 (wheels:cap/cover/hub). The manufacturer stated that the warranty was expired on her vehicle and that the recall was never repaired on her vehicle. It was unknown whether or not her VIN was included in the recall. The vehicle has not yet been repaired, but the contact believes that the vehicle should be repaired according to the recall since the failures are identical. The failure mileage was 90,000 and current mileage was 98,000.

- Baltimore, MD, USA

problem #8

Dec 012008


  • 65,000 miles


At approx. 60K miles, while driving at steady speeds between 40-45mph and 55-65 mph, the engine will stutter/hesitate for less than a second. The occurs at random but seems to be increasing in frequency and intensity lately. From the hundreds of complaints, the most logical in my view are a failed coil pack; the PCM module or a transmission sensor. My research alerted me to the hundreds of unexpected transmission failures that occurred without any prior warning. We are senior citizens and live and commute in a very rural area. If we had a transmission failure as has been reported/described repeatedly, our safety and welfare would be seriously at risk. We don't have another $30K to replace this van, so we are having the transmission rebuilt as a "pre-emtive" measure. We are also replacing the coil pack at this time. The dealer is to evaluate the other suspect components and replace as needed. The cost of these repairs and rental car is estimated to be about $3K. Ford Motor Company will lose a bigger market share by ignoring these complaints. We have been a Ford customer for decades.

- Lore City, OH, USA

problem #7

Dec 242006


  • miles
Does anyone read these? my daughter posted a complaint over a year ago. I just read through a number of complaints about the 2004 Ford Freestar's transmission problems. My son-in-law purchased this van for my daughter for mother's day of 2006 because they were expecting another son and outgrowing their Jeep Grand Cherokee. In the winter of 2006 it started acting up. We had to go get them on christmas eve as they were broke down on the side of a country road on their way to our house for christmas. It was diagnosed a crank shaft sensor. After coming up with the money to replace that, it worked fine for a while. Started again. They were told they most have got a faulty crank shaft sensor and replaced it again. Some time later, it started again. They took it to a transmission specialist that replaced some more sensors. It ran fine all summer. Winter of 2007 started again. Replacing more sensors. Again this winter, it is doing the same thing. This time it was diagnosed as the ABS box on the undercarriage of the van. $400 for the part alone. My daughter was so excited because it ran better than it ever had and they thought they figured out the problem. Now it is doing it again. It sometimes will not go in reverse. Acts like it is taking off in 3rd gear. Stalls out. This is their only vehicle. He is laid off. She is on the verge of losing her job due to attendance as a result of transportation issues. They are struggling like the rest of us to keep their home our foreclosure and their utilities on. The sad thing, they are still paying payments on this van! someone have a heart here! do something! it is the first Ford they have ever owned. My son-in-law says he will buy foreign from now on. I own a Ford also, I will never own another one either. They have contacted the Ford dealership as well as the manufacturer and got no response. This is how they treat their customers. I guess they deserve to go in bankrupt in this economy!

- Centerburg, OH, USA

problem #6

Sep 192008


  • 50,038 miles
My family and I were stopped at a stop sign in our 2004 Ford Freestar. We turned left and almost at the same instant the car's engine started a revving noise and (lucky for us) out of the intersection the car wouldn't go. We were almost smashed by a truck turning the same corner. We had the car towed to our Ford dealership. I was doing research on Ford Freestars and found they had torque converter problems. I called the dealership back and they couldn't give me any updates. At this time I told them of my research and told them it's probable the torque convert. They called back the next day and confirmed it's the torque converter. Called Ford customer service and they told us it's not on recall because 'there hasn't been enough accidents or deaths." There were almost 4 a week ago in il, lucky for my family and I the truck turning stopped in time.

- Montgomery, IL, USA

problem #5

May 302008


  • 52,000 miles
The contact owns a 2004 Ford Freestar. While driving at various speeds, the vehicle would sporadically stall without warning. Usually when the vehicle stalls, it takes approximately 15- 30 minutes to restart. The vehicle was taken to the dealer on three occasions, but they failure could not be duplicated. The failure mileage was 52,000 and current mileage was 57,000.

- Portage, IN, USA

problem #4

May 152008

Freestar 6-cyl

  • 83,000 miles


Failure of cam sensor, then complete failure of transmission 2 weeks later.

- Trenton, OH, USA

problem #3

Mar 022008


  • 58,502 miles
The contact owns a 2004 Ford Freestar. While driving approximately 35-40 mph, the vehicle began to hesitate and the instrumental panel lighting flashed. The vehicle shut off a few minutes later and was towed to the dealer. The dealer stated that water penetrated through the windshield wiper motor area and caused the main computerized system to fail. The instrument panel had to be replaced, the gas line had to be blown out, and the spark plugs were replaced. The insurance company investigation concluded that the failure was due to a product defect. The manufacturer acknowledged receiving the contact's written complaint; however, they would not assist with the $1,200 repair cost that the contact had to pay. The failure mileage was 58,502.

- Springville, IA, USA

problem #2

Apr 252008

Freestar 6-cyl

  • miles
Mrs. Attee was starting our Ford Freestar, when she heard a clicking noise and noticed what she thought was smoke coming from the hood. She(Mrs. Attee) then opened the hood to find a small flame coming from the engine, she proceed to call the fire department. Within 5 minutes the van 's engine was engulfed in flames. When the fire department arrived it was to late, the fire had already done its damage(totaled).

- Taylor, MI, USA

problem #1

May 222007

Freestar 6-cyl

  • Automatic transmission
  • 29,245 miles
While driving my Ford Freestar the engine started to miss. After a short distance it died completely. Luckily, I was on a side road and able to pull to the side out of the traffic. The problem was the result of a manufacturing defect allowing water to leak into the engine compartment and then into the PCM destroying it. At 29,000 miles the PCM had to be replaced without any payment by Ford.

- Salem, MA, USA

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