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 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
78,312 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 wheels / hubs problems

wheels / hubs problem

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2004 Ford Freestar Owner Comments

problem #15

Jul 142015


  • 210,000 miles


The contact owns a 2004 Ford Freestar. While driving at approximately 2 mph turning into the driveway, the two rear wheels detached without warning. The manufacturer was not made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 210,000.

- Gary, IN, USA

problem #14

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 #13

May 112014


  • miles
The contact owns a 2004 Ford Freestar. The contact stated that while driving 65 mph, the contact suddenly heard a loud boom followed by a burning rubber smell coming from the vehicle. The contact franticly pulled over to the side of the road and first thought she had a flat tire but upon inspection, the contact noticed there was severe corrosion on the rear wheel well wall. The contact took her vehicle to the dealer, who stated that the contact would have to leave her vehicle for 3 to 5 days however, the contact declined. The manufacturer was made aware of the failure. The vehicle was not repaired and the failure mileage was unknown.

- Old Bridge, NJ, USA

problem #12

Aug 012013

Freestar 6-cyl

  • miles


2004 Ford Freestar. Consumer writes in regards to wheel well rusting recall notice. The consumer stated rust developed on the driver's side door in 2010, at the time the vehicle was purchased, the consumer bought amor protection for rust. The consumer put in a claim, and the vehicle was repaired. However, one year later, the rust returned, only this time, the consumer was denied a second claim. A couple of years later, the third seat bracket fell apart. The consumer received a recall about the wheel well rusting. The consumer made an appointment at the dealer. The dealer informed the consumer, as they were cutting away at the rust. It was discovered the frame was also rusting, and it was dangerous to drive the vehicle, or to even try and fix the rust problem.

- Signal Mountain, TN, USA

problem #11

Apr 292013

Freestar 6-cyl

  • 54,000 miles
The contact owns a 2004 Ford Freestar. The contact stated that while driving approximately 10 mph, there was a loud noise coming from the front end of the vehicle. The vehicle was taken to a private mechanic where it was diagnosed that the front hub, rotors, and wheel bearings needed to be replaced. The manufacturer was made aware of the failure but stated that NHTSA campaign number: 04V446000 (wheels) was expired. The vehicle was not repaired. The approximate failure and current mileage was 54,000.

- New Castle , DE, USA

problem #10

Mar 012010

Freestar 6-cyl

  • 50,000 miles
Check tires & traction control off light comes on daily.

- Randolph, NJ, USA

problem #9

Feb 012013


  • 130,000 miles


The problem is the same that is described in EA12003. The attaching bracket for the rear seat fell out while the seat was folded into the floor. It became lodged in the inner portion of the rear wheel assembly. If this would have happened at high speeds, somebody could have easily been killed, by the rear wheel becoming restricted or this heavy plate bouncing down the road at another vehicle. The bracket is a U bracket attached to a plate that is welded flush to comprise part of the wheel well. To temporarily keep from losing the bracket, I held the bracket in place while setting the seats upright again so that the seat itself is holding the bracket in. There is now water from the road getting up into the passenger compartment. I hope that Ford issues a recall or offers a bolt on replacement soon. I've been mostly happy with this vehicle otherwise. (there are no other prices rusting or falling off obviously).

- Newbury , OH, USA

problem #8

Dec 072012


  • 47,000 miles
The contact owns a 2004 Ford Freestar. The contact was driving approximately 10 mph into a driveway and heard a loud noise from the front end of the vehicle. The front passenger side then collapsed to the ground, which caused the tire to become completely detached from the vehicle. The vehicle was towed to an independent mechanic for diagnosis. In 2004, the vehicle was repaired under NHTSA campaign id number 04V446000 (wheels:cap/cover/hub). The manufacturer was notified of the problem. The approximate failure mileage was 47,000. The VIN was unavailable.

- Collingswood, NJ, USA

problem #7

Oct 132012

Freestar 6-cyl

  • 116,000 miles
Noticed a panel loose in the rear driver's side wheel well while removing the wheel. The panel was completely rusted and separated from the wheel well, with only something attached to it on the interior keeping it from falling off. Took it to a body shop, where it was determined that this panel is the rear seat anchor and the seat latch was the only thing keeping it from falling off. The estimate for repair is $906.99. The rear seat anchor was removed and the hole temporarily taped closed, and the rear seat is not safe and cannot be used. Contacted the dealer to see if any recalls exist for this condition and was told there are none. Currently trying to decide whether or not to repair the vehicle. The vehicle is well maintained and the condition of this panel/anchor is unusual when compared to the rest of the vehicle.

- Yorkville, IL, USA

problem #6

Jul 292012

Freestar 6-cyl

  • 109,000 miles
Driver's side seat mount on third row seat failed side panel in wheel well corroded and failed displacing panel into tire sidewall. Passenger side panel showing signs of failure. Ford dealership bodyshop refuses to work on issue for fear of future liability. Dealership states that corrosion issues beyond normal.

- Abilene , KS, USA

problem #5

Jul 022012

Freestar 6-cyl

  • 104,000 miles


The rearmost seat in my minivan will not latch down on the rear drivers side. The rear axle 'moans' at times and makes a rotational shimming sound. Upon inspection, I am told there is severe rust in the wheel well where it locates to the seat attachment. The dealership says it is unusual, although I understand your Agency is investigating just this thing in 2004 Freestars.

- Lakewood , OH, USA

problem #4

Dec 132008

Freestar 6-cyl

  • 88,584 miles
Issues noticed with electrical systems within a year of purchasing brand new vehicle. Dealerships never found anything wrong. While driving down the road, vehicle would lose power. Radio would go out, all lights on dashboard would go out etc. Then all of a sudden they'd all come back on as if nothing happened. Noticed mostly during rainy and humid days. Then once in a while van would chug and act doggy. In December 2008, while driving down a busy city street, van just stopped "driving" and would rev. Didn't have money to fix until April of 2009 so it sat in our driveway. Had it towed to transmission shop after calling Ford dealership and was told it was double the cost for them to fix. Transmission shop told me that the splines stripped off the torque converter causing the transmission to fail. Repair cost for tranny rebuild #1: $1,830.97. Shortly after, the A/C stopped working (summer 2009). Replaced condenser for price of parts as neighbor who's a technician provided free labor. Van ran okay for about a year. Then in summer 2010, started running sluggishly again and still had issues with power loss (as stated in beginning). Found info online about everyone having issues with PCM so replaced that as well for $500. Worked for a couple months but then in December 2010 van started having issues with power loss again and chugging. Little did I know, this was the start of the tranny beginning to fail again! July 2, 2011 tranny failed again. Doing 50mph in road construction zone. Again, told by transmission shop (different shop as we were 9.5hrs from home), that the torque converter failed again and tranny needed to be rebuilt. Cost to rebuild tranny #2: $1,850. Still having issues with sluggishness, thinking water getting into pc still. Tire pressure lights have been on for years, having issues with sliding doors, back up sensors, A/C etc. I'm tired of this lemon!!!!!

- Ironwood, MI, USA

problem #3

Nov 142006


  • 35,000 miles
Very high pitched squealing noise coming from front wheels. Noise begins approximately 15 minutes after beginning driving. Noise is intermittent but very irritating to passers by and other drivers. Noise "lightens" or lessens when brakes are applied and when slightly turning the steering wheel. I believe it to be wheel bearings/hub bearings. Very similar description to complaints I have read and I believe it is related to the recall #04S24. My vehicle was produced at the Oakville assembly plant, but was produced before the dates listed in the current form of the recall. My vehicle only has 66,000 miles on it and is very well maintained. I request that this recall be expanded immediately and that remedy is offered swiftly.

- Marysville, OH, USA

problem #2

Mar 292009


  • 23,500 miles
Purchased a Ford Freestar in 2004. Last July, I noticed puddles of oil in my driveway and a kick in the wheel when turning. Proceeded to my mechanic, on an emergency basis, and found out that it had to be fixed immediately. It turned out to be the rack and pinion. I checked the recall list with NHTSA and found that Ford recalled approximately 34,000 cars with the problem. The report indicated that the linking fluid good cause smoke. My VIN number did not match the recall list. Just recently(March,2009),I started hearing screeching sounds coming from the car. It would subside when going around curbs etc..turning the wheel slightly -would eliminate the sound. Again, I checked recalls and found recalls for hub problems. If not fixed the wheel attached to the axle would caused steering difficulty and a possible crash. Checked recall VIN number and it did not match. Contacted Ford problem bureau and registered a complaint. I have presently 23,500 miles. I have registered a complaint with the federal trade commission. I believe that there are other 2004 Ford Freestars with the same problem. The car cannot be driven for fear of an immediate mechanical break down. Ford should step forward and correct the situation for those owners who have spent money to repair the problems. I cannot sell the vehicle. How can I imposition others!I 'm glad there wasn't a negative occurrence where injuries existed. As a senior citizen, cost of continuous repairs and the safety issue prevails.

- Florham Park, NJ, USA

problem #1

Feb 012009


  • 22,000 miles
2004 Ford Freestar sel - ~23000 miles on the vehicle I have been hearing an intermittent squealing noise coming from the right front wheel. I brought the car to the dealer for regular maintenance, but they said nothing about the noise. The noise continued to get worse. I searched on the internet for people with similar problems and found out about a recall for the front hub, rotor, and wheel bearing (id #52707). My VIN was not included in the recall notice. When I brought the car back to the dealer, they said that the front right wheel hub and bearing were the cause and need to be replaced. This will cost me $420. I told them about the recall notice and said there was nothing they could do if the car was not on the original recall list. I called Ford and they said they would only pay for the issue is NHTSA included my VIN in the recall list. I am writing this complaint to see if my vehicle can be included in the recall list.

- Milford, MA, USA

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