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 / 0
Injuries / Deaths:
2 / 0
Average Mileage:
93,984 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 fuel system problems

fuel system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Ford Freestar:

Unsubscribe any time. We don't sell/share your email.

2004 Ford Freestar Owner Comments

problem #6

Feb 242016


  • 81,000 miles


The contact owns a 2004 Ford Freestar. The contact stated that while parked, there was a strong odor of fuel outside of the vehicle. The entire fuel tank exhibited rust corrosion as a result fuel leaked from the outer part of the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 81,000.

- Ooltewah, TN, USA

problem #5

Jan 122016


  • 87,000 miles
The contact owns a 2004 Ford Freestar. While driving approximately 70 mph and suddenly on an elevation, the vehicle shook, decelerated, and lost power without warning. The contact pulled into an independent mechanic's shop where the technician changed the fuel filter. The failure recurred a few days later. The check engine light illuminated. The vehicle was taken to another independent mechanic who did not diagnose the failure. The manufacturer was made aware of the failure and stated that there was no recall. The VIN was unknown. The vehicle was not repaired. The failure mileage was 87,000.

- Poughkeepsie, NY, USA

problem #4

Jan 192015


  • 185,600 miles
As I proceeded to make a left hand turn, @ a permittible speed 25 M.P.H. I could hear noise emanating from the rt. Frt. Side of the veh. Fuel sys. Further ck'ing needed.

- Tulsa, OK, USA

problem #3

Aug 112013


  • 52,490 miles


Van started running poorly suddenly, then would not run at all. After shutting down and allowing cool down time, restarted van and it would not go into gear. Ran well in park or neutral, but shifting into any gear would "clunk" and the engine would immediately quit. After 5 days of troubleshooting, traced trouble to engine PCM after reading in on-line forums about it. Found PCM wet and pins on PCM and contacts on wire harness corroded and green due to water leaking past cowl-to-body seal. The PCM connector is not sealed, so if water does drip on it, it is dripping directly onto back side of the contacts and Ford did release a tsb about this issue but not a recall. Tsb says to remove some plugs from body (my van is severely rusted in one of those 2 spots), seal around clips that hold plastic cowl to body with silicone sealant and add additional weather stripping on the outer edges of cowl to try to prevent water. I had to replace my PCM. Had my wife been on the highway when this happened, there would have most certainly been an accident or injury.

- Clifton, NJ, USA

problem #2

Oct 012008


  • 50,000 miles
Every single time gas is being pumped into the car the pump stops several times. It can take up to 20 minutes to completely fill the gas tank. Not only does it just stop, it frequently spits gas back out. The gas, which is a chemical, has given at least 2 people chemical burns on multiple occasions. Ford has been contacted and while this is a "known issue", they refuse to replace and/or repair unless I pay for it out of my pocket. This is a manufacturing defect, it happens often enough to be a known issue, it is dangerous in many different ways and I believe that this should most definitely be a recall due to the chemical burns that have already happened. Also the potential devastation that could happen if someone at a gas station throws a still burning cigarette butt down and it lands in the remains of the gas that has been spit back out and onto the ground. Although no smoking signs are posted, I have seen hundreds of people still smoking while pumping gas.

- Riverside, CA, USA

problem #1

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

Not what you are looking for?