really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
1 / 0
Average Mileage:
85,032 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.

2005 Ford Freestar electrical problems

electrical problem

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2005 Ford Freestar Owner Comments (Page 3 of 4)

« Read the previous 20 complaints

problem #39

Oct 132012

Freestar 6-cyl

  • 114,351 miles


Having a similar problem to others with my 2005 Ford Freestar. Water getting into PCM and causing problems. Took vehicle to dealership for torque converter recall and they noticed water in the PCM. They dried it out and vehicle ran fine for two weeks. Had significant rain last night and problem happened again. This is an obvious flaw in this vehicle and needs to be fixed.

- Bexley, OH, USA

problem #38

Oct 242012

Freestar 6-cyl

  • 85,000 miles
I was driving my minivan back to work from lunch. It cut off as I took a turn. I stopped the vehicle and restarted it. As I began to go again, it cut off again. I pulled over and restarted the vehicle. I was right outside my work parking lot so I pulled in and parked. I called egan automotives because they are located right beside my work. During my break I drove it to their place of business. My minivan check engine light was on and it was acting sluggish. I left the vehicle with them overnight. Egan automotive called me and told me that there was moisture getting into the computer box. They said that Ford knew about this problem and were selling a kit that will insulate the computer box. I called Ford and they won't help even though the placement of the computer box under the wiper blade vents was there brilliant idea. Looking online this seems like a pretty common problem, yet Ford won't recognize it and fix it. This is going to cost me $300, which I feel I'm not responsible for. A vehicle cutting out while driving is a safety hazard. Can you help get this resolved?

- Kaysville, UT, USA

problem #37

Oct 182010

Freestar 6-cyl

  • 56,000 miles
I have had the car stop after and during rainy days. Most recently the car would not start or move during a heavy rain. I have had to wait days until the car dries out for the car to move. Have taken it to the shop after several instances of this same occurrence. They can not find out what is wrong as the car runs ok" after researching on the internet I have come to the conclusion that it is water leaking on and into the PCM causing the car to not start or move. Ford dealership has not been able to solve the problem or have a solution"

- Ada, MI, USA

problem #36

Jul 162012

Freestar 6-cyl

  • miles


Add-on info for complaint #10472027. The date stated for the problem with the PCM was merely an arbitrary start date for our problems, which was required to proceed with the complaint. We have had continual problems for at least near 2 years with the vehicle, but no mechanic (including Ford's) has been able to accurately confirm the basis of such issues. Our assessment of a damaged PCM is based on research of on-line complaints from other Freestar owners which seem to almost perfectly match our situation, as well as the fact that our mechanic had to remove water from the computer compartment. Currently, we are in search of a replacement computer, but they are almost impossible to find.

- Jasper, GA, USA

problem #35

Apr 052011


  • miles
2005 Ford Freestar PCM problems. Symptoms include intermittent incidences including vehicle's failure to start, running rough, improperly accelerating, refusing to move forward/backward, and other random problems. The fuel system components/camshaft sensor/etc, as well as the transmission have been replaced on the vehicle, but all of these issues still exist. Codes do not show up on mechanic's diagnostic computers unless the car is actively having the problem, which seems to rarely happen. Mechanics, including the local Ford dealership, has not been able to confirm the problem with the PCM; however, our mechanic did find water in the computer module. He dried it out and resealed it, in hopes of resolving the issues we were having. The problems have continued though and despite lack of codes, all indications are that the computer is no longer good. Another problem is the fact that getting a replacement PCM is nearly impossible. The demand for Freestar reconditioned computers is so high that we've not been able to find one to replace the bad unit in the van. (apparently, new PCM's are not available at all.) after seeing the massive number of on-line complaints which are so similar to ours, I cannot believe that Ford shut the case regarding the computer problem. If the diagnosis of failed PCM's is almost impossible to achieve, Ford simply chooses to ignore the obvious. (read all of the complaints on NHTSA.dot.gov.) poor placement of the PCM on the back of the vehicle wall has allowed water to run off of the windshield into the unit, but Ford will not take ownership in this problem. How many people have to risk having a wreck and possibly dying due to water-damaged components? it is unfortunate and unnecessary. One last question... is it possible that the transmission problems (currently on recall) be related to the water-damaged PCM's?

- Jasper, GA, USA

problem #34

Dec 302011

Freestar 6-cyl

  • 102,000 miles
Was stalled out several times during the month of January and February of this year. It would just stop responding. It acted much like a transmission going out, but that was not the problem. After multiple towes and trips to the mechanic to attempt getting this vehicle repaired, it was determined that the PCM had gotten water inside and had to be replaced. I spent several thousand dollars trying to get this vehicle to run as well as it had before. Once the PCM issue was discovered, it did run much better, but by this time I had lost my faith in the vehicle. I cannot believe that Ford positioned a computer component where water would run down onto it, and they have not been forced to fix this issue. As a result of all of my problems with this vehicle, after many years of being a Ford owner, I sold this van and purchased a Chrysler Town & Country.

- Portage, MI, USA

problem #33

May 012012

Freestar 6-cyl

  • 113,000 miles


I was driving 45 mph in a heavy rain when my vehicle began to sputter and check engine light began flashing. I started to pull over, but light went off and engine ran fine. After several days of rain engine would hesitate in acceleration and would feel like it was missing. It began only occasionally and usually when traveling up hill. It progressively got worse, especially after rain or being washed. Investigated and found this to be a common problem with this model with the power control module getting wet. Today while driving on the interstate check engine light began flashing and engine hesitated, then check engine light stayed on. Very dangerous situation to feel like my van was going to stall at 70 mph with my family in the car.

- Morganton, NC, USA

problem #32

Oct 082010

Freestar 6-cyl

  • 47,395 miles
After driving in or after a hard rain, the engine light comes on and the engine runs very rough and often stops. Has happened while driving on highway at 55mph. Cowl was removed at dealership to prevent water intrusion in oct2010, but same problem started happening again in 2012...

- Wallingford, PA, USA

problem #31

Jun 212012


  • 128,000 miles
I was driving my Freestar home, pulling into my complex when the battery light came on, then a second later the brake light, then all the power to the van was lost. I had no control, the entire electrical system went out, the engine shut off, I had to rub the van up against the curb to stop it. When I got it going again and parked in my parking spot the battery light came on again and I lost all power again. The next day I replaced the battery as I was told it could be a battery issue, but even with the new battery the light was still on. I had the alternator and the battery cables checked and it was fine. Then I was told it maybe the PCM which is a known issue with this model and what I experienced is the identified issue...this is very serious as I was bring home my family home and we just got off the highway like 5-10 minutes before this thing shut down on me, if this was the highway we could have been seriously hurt. Plus now I can't even drive because the part is not available, it's on back order, so this must mean a lot of people are having this issue. We need to have a recall on this before people get hurt or killed, especially when it's a known issue nhthqnwws111.ODI.NHTSA.dot.gov/acms/docservlet/artemis/public/pursuits/2009/dp/insl-DP09004-35644P.pdf !!!!!

- Brampton, FL, USA

problem #30

Apr 012012

Freestar 6-cyl

  • 98,000 miles
Was on a very busy highway. The Freestars dash lights lite up and went back off. Ac cut off then everything started working again. About 30 seconds later the Freestar died at 65. I was able to coast to a stop on the shoulder. Again on May 5 2012 the lights started flickering and the ac started to blow hard and it would slow back down then the dash lights ABS, brake, battery lights would blink on and off then the Freestar died again at 70 mph. Brakes didn't work I was going through a intersection and had to use the E brake. Freestar has done this several times over the last month I just hit the high spots. It has had test after test and I'm always told a different story! I just want my van fixed before someone gets hurt or killed.

- Garvin , OK, USA

problem #29

Feb 072012

Freestar 6-cyl

  • 102,340 miles


When driving down the road the van will suddenly lose all forward momentum and drift momentarily until it will just as suddenly resume forward momentum and continue like normal. When this happens, the rpms drop off like the vehicle is stalling or fuel starved (however it has no hesitation like its running out of gas) no warning lights come on and there is no pattern to when or how it happens. However, the problem has been getting progressively worse and now it is noticed that it has a higher tendency to do it when it is raining or there is high humidity. It does it at all speeds from 25mph to 70mph. Ford dealership has looked at the van and could not get it to reproduce the problem when they had it. However, they stated this does not sound like a torque converter problem addressed under safety recall notice 11S25/ NHTSA recall 12V-006. This is a very dangerous problem and has almost caused several accidents as I have no warning the problem is getting ready to happen and have no way to notify other motorist of my sudden and quick deceleration.

- Lynchburg, VA, USA

problem #28

Sep 212011

Freestar 6-cyl

  • 51,379 miles
On September 21, 2011 I noticed that my 2005 Ford Freestar was hesitating when I pulled out of a parking spot in front of my home. I was able to get to my final destination, a local supermarket, without incident but could tell that the car was not shifting gears as smoothly as I was accustomed to. On the return trip home, upon merging onto the expressway I typically take, my Freestar's engine began to sputter then immediately shut down. All power to the engine was lost. Power steering was lost as well making the car impossible to maneuver. The electrical system completely shut down and I was forced to come to a complete stop, shift into park and reengage the ignition. From that point on, until I arrived home, the Freestar would not shift beyond second gear. If I made an attempt to accelerate, again the engine would sputter and all power to the engine, power steering and electrical systems would shut down completely. I managed to get home that day by stopping and restarting my Freestar what I can only estimate to be 50 to 75 times. The most harrowing part of this experience was the lost of power and control without warning. Prior to this day, I had never experienced anything remotely like this with the Freestar, and then from one day to the next, I was helpless on the expressway expecting a fatal collision with an unsuspecting driver.

- Brooklyn, NY, USA

problem #27

Jan 242012

Freestar 6-cyl

  • 71,900 miles
Was driving around 30mph then the RPM's went up to 5000 let off gas RPM slowley went down..2nd time it happened took it in they said it was a sensor "fixed" it...the 3rd time was going threw an intersection died on me in middle of intersection almost got smashed by oncoming traffic with my kids in the van...had it towed they could not find anything wrong....4th or 5th time was going to work got of highway rpms went up to 5000 and the van wont go no wheres now...no reverse no drive just sits there sounding like [xxx]they way Ford made it...now waiting on them to tell me whats wrong with it.... information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Rensselaer, NY, USA

problem #26

Aug 052006

Freestar 6-cyl

  • 21,223 miles
This vehicle has died on me numerous times while driving down the freeway or around town driving. It has been very scary and a miracle we weren't killed. The first time it happened in 2006. The Ford dealer had no idea what it was, finally discovered it was happening in cold weather, moist air or rain. The PCM was getting wet. They put foam and sealed with an adhesive. It started again in 2008 had to be resealed. It has started again in 2011 and 2012 it is very scary and you never know when you will lose power. It is very expensive to have fixed. Ford knows this was a bad design. They are waiting for someone to get killed and be sued before they will take responsibility for this problem. My van is now parked, while I try to get the money together to have it sealed again. Hemborg Ford doesn't even offer a discount for the repair. They are not concerned at all that the vehicle dies while you are traveling down the freeway. This van has had numerous recalls, it should have had one for the PCM but so far it has not. I guess they are waiting for someone to die. Online there is a lot of complaints on this same issue from people from all over the United States.

- Norco, CA, USA

problem #25

Mar 112012

Freestar 6-cyl

  • 141,000 miles
PCM failure moisture gets into PCM because of design flaw and causes electrical shorts and vehicle jerks and cuts out. Loses power.

- Huber Heights, OH, USA

problem #24

Jun 202011

Freestar 6-cyl

  • 48,424 miles
Van started acting like the key was being turned off and on. Misfire was so bad that van was like riding a bucking Bronco. Pulled to the side several times as I thought we would not make it home. Got home from Sunday diner and took to local dealer the next day on 6/20/11. Installed 1F1Z 6B288 ba sensor. Back to dealer on 6/28/11. Installed 164R4901 foam strip along with sealant. Back to dealer on 7/5/11. Installed. Installed xl3Z 9F472 aa sensor. To independant repair shop on 12/2/11. Installed yfiz-7H103aa sensor. Back to same repair shop. Installed 5F2Z12A650 bc PCM module. That seemed to resolve the problem as van is running better than for the last 2 years.

- Corydon, IN, USA

problem #23

Jul 162010

Freestar 6-cyl

  • 76,000 miles
After a rain storm my van experiences problems with the power control module. The transmission will not operate correctly. This is the third time this has taken place and always associated with a rain storm. This time the engine will not start.

- Kansas City, MO, USA

problem #22

Jun 162011

Freestar 6-cyl

  • 97,950 miles
PCM (power train control module) has gotten wet and causes car to not drive. Lose power. Not start. Lunge, lurch forward. Won't engage in drive or reverse. I have replaced PCM 6 times. Broke down 5 times. Had van towed 5 times. Left van at repair shop for months at a time to diagnose problem. Finally moved the PCM to the inside of van so that it won't be effected by water. Ford has refused to acknowledge problem despite a tsb being issued. Furthermore, I replaced the transmission and a recall has been issued but Ford will not review my receipts for the transmission until letters go out. Total stonewalling by Ford.

- Lakewood, OH, USA

problem #21

Sep 152007

Freestar 6-cyl

  • 41,000 miles
9/2007 my husband, myself, and our 5 children were driving to my mothers house and out of the blue the van just stopped accelerating. We had the van towed to the dealership that we bought it. They told us that we needed a new transmission at 41,000 miles (just out of warranty) $2000 oop!! we had the trans replaced and are now 12/2011 having the same issue again. (just over 90,00 miles) we owe 2000$ on the van and the cost of repairs are over that. This has to be a safety issue..children in car + car randomly stopping!! I just don't understand how a van bought new off the lot can be on its 3rd transmission on less then 100,000 miles. We will never buy a Ford again and after doing a lot of research I have found 1000"S of owners with the same issues...its a shame Ford will continue to allow customers to pay for their faulty products!

- Macomb, MI, USA

problem #20

Oct 312009

Freestar 6-cyl

  • 87,943 miles
Drove to the store that day. We have been having a lot of rain. When done at the store got in the van and it started fine but when you pressed on the gas pedal the RPM would race up but the van would go no where. The Ford dealership replaced the PCM sensor because it had water in it. It was running but not like before. Took back the van on 4/21/11. Engine runs fine. Driving down the road and van started sputtering like it was choking. Stopped the van and shut off the engine, turned it back on and it ran fine. Two days later had the same problem but I was at a stop sign and the van did not want to move forward. My husband barely got it to the dealership, it just completely died on him once. Once the dealership had it they said they couldn't find anything. Just had a speed sensor changed on it on 11/15/11 they had the van for 8 days trying to figure out what is wrong. Now just tonight, when you put the van in any gear the rpms drop and the shifting is delayed. I am guessing something is wrong with transmission. How can I ever trust the Ford company again" I have been reading too many of the same problems. We are going to take the van tomorrow to see what is wrong with it again?! help!!! I also read I need to call Ford for them to have some many complaints for a recall is this true"

- Monticello, IN, USA

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