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:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
68,597 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

problem #8

Mar 182012

Freestar 6-cyl

  • 150,500 miles


Driving North on Minnesota highway 169 at 65mph and notice smoke coming from the engine compartment. I immediately pulled over onto the shoulder and within three minutes there were flames coming from the engine compartment as well as smoke. There was nothing wrong with my vehicle and it was running well when all of a sudden it just started smoking and then it burst in to flames.

- Le Sueur, MN, USA

problem #7

Aug 182011

Freestar 6-cyl

  • 78,000 miles
My husband was driving on a 4 lane hwy in pensacola, fl when my 2004 Ford Freestar suddenly stopped pulling. No forward, no backwards, neutral, nothing and the rpms went extremely high. Zero warnings, and in heavy rush hour traffic. It is only due to my husbands race car driving experience and quick reaction time that he was immediately able to get the van on the side of the hwy. My husband and our two boys thankfully were safe but they were stranded in intense Florida heat. I have had a lean fuel, various electrical, coil pack and PCM issues since I got the van June 2007. The Ford dealership, and the easterns dealership I purchased the van from, could not figure out the problems. While under warranty, easterns worked on it but none of the issues were ever able to be fixed. I choose the Freestar for its safety features so I knew I had a safe way to Transport my children. This is no longer the case, I do not trust Ford to take care of their defective products and I will not purchase another Ford.

- Milton, FL, USA

problem #6

Mar 052010

Freestar 6-cyl

  • 123,000 miles
Our Freestar spits and sputters during wet weather. Mechanic changed sparkplugs, but no change. Only happens during wet times. Vehicle stalled in traffic with daughter driving. Finally was able to restart vehicle and get it off the road.

- Norwalk, WI, USA

problem #5

Oct 312009


  • 78,000 miles


After a day of family festivities, 2 1/2 hours away from home, I packed my husband, two daughters, son-in-law, granddaughter and myself into my 2004 Ford Freestar van. I was driving down a very rural two lane road, in total darkness when it started. I was leaving a very very small town and accelerated from 30 to 55. Everything was fine until I reached 62 mph. The van seemed to misfire and lunged. Everyone asked was it was. I had let off the gas a bit and tried not to go over 60. As we continued, the van lunged again, but now I was only going 55, and then again and again, going slower and slower. My husband assumed I had a problem with the gasoline and told me to blow it out but I told him when I pushed on the gas, there was no response. The check engine light went on and then it got bad. I could see headlights coming up in my rear view mirror. I thought about pulling off to the side, but as the van started to loose power, I realized that there was no shoulder and that there was a ravine. I was pumping the gas pedal and the van would intermittently respond by lunging forward and then pausing, just like a bucking Bronco. The movement was so thrusting it woke up my granddaughter from a sound sleep. I managed to put my flashers on but I couldn't get off the road. I realized that I needed to make it to the next town, as being stranded in that area would be very dangerous for anyone getting out of the vehicle or anyone being left behind in the vehicle. I am amazed that no one got killed because the van would totally loose power and shut off. I was dropping to neutral to restart it, only to have the same thing happen again, pumping the gas, making it a little way and then the engine losing power. This happened four or five times until I made it into the next town, where I drove down hill with no engine, steering or brakes, and coasted into a gas station. It would not go into reverse and was left 2 hours from home, awaiting arrangements to picked up.

- Crystal Lake, IL, USA

problem #4

Aug 282009


  • 85,000 miles
The contact owns a 2004 Ford Freestar. The contact stated that while driving 55 mph the rpms dramatically increased, then the vehicle stalled as a consequence his risk for vehicle crash and serious injury were increased. The vehicle has not been diagnosed by the dealership, therefore the cause of the failure is unknown. The current and failure mileages were 85000.

- New Brunswick, NJ, USA

problem #3

Aug 052005


  • 250 miles
The contact owns a 2004 Ford Freestar. The contact started the ignition and placed the gear shifter into drive. The engine began to rev and the transmission immediately locked up. The contact had to make several attempts before the vehicle would operate. The vehicle was towed to an authorized dealer for diagnostic testing. The technician repaired the vehicle. In addition, the rear brake assembly failed, which was not covered under the warranty. The vehicle was taken to an independent mechanic for repairs. On a separate occasion, the vehicle was taken to an authorized dealer for identical failures. The vehicle also experienced electrical failures relating to the exterior lighting. The technician recommended that the transmission be rebuilt or replaced. The vehicle has not been repaired. The failure mileage was 250 and current mileage was 52,000.

- Fort Meade, MD, USA

problem #2

May 152005

Freestar 6-cyl

  • Automatic transmission
  • 34,000 miles
Consumer saw an oil leak under vehicle. Jiffy lube found a rock lodged between oil pan and a part of the frame or support member. Oil pan worn through because of rock. Jiffy lube will not remove rock because they said it would do more damage. Manufacturer said to call dealer.

- Limington, ME, USA

problem #1

Dec 042004

Freestar 6-cyl

  • Automatic transmission
  • 25 miles
Brakes squealing, air bag light comes on, engine hsa alot of pinging hioway speed 60 and up.

- Shawnee, KS, USA

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