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Ford · Known Issues

2004-2007 Ford Freestar Problems: 16 Known Issues

2004-2007 model years · 160+ owner reports · Updated October 2026

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Issue summary

According to Au7o's analysis of 160+ owner reports, the 2004-2007 Ford Freestar has 16 documented known issues, with 5 rated critical. The most serious are Power Liftgate Free-Falls When a Gas Strut Fails (Recall 06V069000), Torque Converter Shudder and Transmission Failure ($1,500-$3,500 repair), Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10), Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000) ($250-$600 repair) and Power Steering Low-Pressure Line Unseated at the Rack and Pinion (Recall 03S09 / 03V457000) ($0-$250 repair). The most commonly reported issue is Rear Axle Trailing Arm Bushing Deterioration with 160 owner reports. Across all issues with published estimates, repair costs range from $30 to $3,500. DIY maintenance guides at au7o.io.

In This Article

  • Freestar Suspension3
  • Freestar Safety/Recalls2
  • Freestar Electrical2
  • Freestar Steering2
  • Freestar Transmission1
  • Freestar Emissions1
  • Freestar Brakes1
  • Freestar Interior1
  • Freestar Fuel System1
  • Freestar HVAC1
  • Freestar Body/Panels1
  • Recalls6
  • FAQ
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In This Article

  • Suspension3
  • Safety/Recalls2
  • Electrical2
  • Steering2
  • Transmission1
  • Emissions1
  • Brakes1
  • Interior1
  • Fuel System1
  • HVAC1
  • Body/Panels1
  • Recalls6
  • FAQ

All 16 Known Issues

NHTSA Recalls6 recalls

SEATS

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.

Campaign #13V08100007/03/2013

POWER TRAIN:AUTOMATIC TRANSMISSION

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.

Campaign #12V00600009/01/2012

FUEL SYSTEM, GASOLINE

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

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Frequently Asked Questions

What are the most common Ford Freestar problems?

According to Au7o's analysis of 160+ owner reports, the 2004-2007 Ford Freestar has 16 documented issues. The most frequently reported are: Power Liftgate Free-Falls When a Gas Strut Fails (Recall 06V069000), Torque Converter Shudder and Transmission Failure, Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10). Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Freestar reliable?

The 2004-2007 Ford Freestar has 16 known issues documented across 160+ owner reports. 5 issues are rated critical: Power Liftgate Free-Falls When a Gas Strut Fails (Recall 06V069000) and Torque Converter Shudder and Transmission Failure and Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10) and Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000) and Power Steering Low-Pressure Line Unseated at the Rack and Pinion (Recall 03S09 / 03V457000). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Freestar problems?

Repair costs for known Ford Freestar issues range from $0 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Ford Freestar is the most reliable?

Reliability varies across model years of the Ford Freestar. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2004-2007 Ford Freestar with 16 documented issues documented across 160+ owner reports.

What is the 2005-2006 Ford Freestar Power Liftgate Free-Falls When a Gas Strut Fails (Recall 06V069000)?

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 160+ owner reports, NHTSA recalls, TSBs, and automotive forums.

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ALL YEARS2007200620052004

A batch of 2004 Freestar (and Mercury Monterey) minivans left the plant with front wheel hub assemblies that were not heat treated to specification. The under-treated hubs develop small fatigue cracks that propagate under normal load. If a crack runs to completion the wheel can separate from the vehicle, which is why NHTSA classified this as a wheel-separation defect rather than a bearing noise complaint. Roughly 34,000 vehicles were named. Because this is a 2004 build-quality defect it does not apply to later model years, and it is a different failure than the ordinary mileage-related hub bearing wear that also affects these vans.

Common Symptoms

  • Growling or grinding from a front wheel that changes with speed
  • Humming that changes pitch when steering left or right
  • Vibration felt through the steering wheel
  • Wheel play when rocked at 12 and 6 o'clock
  • ABS warning light from a disturbed wheel speed signal

How to Fix

Free recall remedy: under Ford campaign 04S24 dealers replace the front hub, rotor, and wheel bearing assembly at no charge. The recall has no expiration for the affected VINs, so a 2004 Freestar should be run through the NHTSA VIN lookup before purchase. If the VIN is outside the recall population, a failing front hub is replaced as a complete sealed hub/bearing unit; the bearing is not serviceable separately.

Typical repair cost:$250 - $600

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026
Community reported
160 owners

The Freestar's rear twist-beam axle trailing arm bushings crack and deteriorate, causing the rear end to feel loose and unstable. Worn bushings allow the rear axle to shift, causing poor alignment, inner tire wear, and a wandering feeling at highway speed.

Common Symptoms

  • Rear end feels loose or unstable
  • Inner rear tire wear
  • Wandering at highway speed
  • Clunking from rear over bumps
  • Rear end shifts during braking
  • Squeaking from rear suspension

How to Fix

Replace both trailing arm bushings. Aftermarket polyurethane bushings last longer than OEM rubber. A rear alignment should be checked after bushing replacement to verify toe settings.

Typical repair cost:$200 - $600

Research This Issue

Based on 160 owner reports

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Community Reported
High Confidence160 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026

Separate from the 2004 recall on front hubs, the Freestar's rear hub/bearing assemblies wear out as a routine high-mileage failure across all four model years. Owners describe a speed-dependent hum or growl felt through the seats rather than the steering wheel, which is the giveaway that it is a rear bearing rather than a front one. A notable diagnostic trap on these vans is that the bearing can growl with no detectable play at the wheel, so the common 12-and-6-o'clock rock test returns a false pass. Because the rear bearing carries the ABS tone ring in these vans, a failing rear hub often lights the ABS warning lamp as a secondary symptom.

Common Symptoms

  • Speed-related humming or growling from the rear of the van
  • Vibration felt from under the seats
  • Knocking or clunking when cornering
  • Noise present with no detectable wheel play
  • ABS light on

How to Fix

Confirm the growl by road speed and side localization. Replace the complete sealed hub/bearing assembly, and consider the axle pair on a high-mileage van.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • OEM/OES 92-00442ON rear wheel-hub assembly
    $229

    2004-2007 Ford Freestar FWD with four-wheel ABS; fits left or right rear. Confirm ABS equipment and order two if replacing the axle pair.

    BuyAutoParts

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$200 - $500

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Community Reported
Low ConfidenceVerifiedReviewed Aug 2026

Recall 06V069 / Ford 06S42 applies to certain 2005–2006 Freestar vans with the power-liftgate option, built through December 13, 2005. After powered opening, the original system disengages its motor; a failed support strut can then allow the gate to fall and injure someone beneath it. The software remedy enables controlled motor-assisted lowering if a strut fails; it does not replace the strut.

Common Symptoms

  • Liftgate falls after powered opening when a support strut fails
  • Liftgate does not remain open; after the recall update, controlled closing with a rapid chime can indicate a support fault

How to Fix

Contact Ford to check the VIN and campaign history and arrange the 06S42 module update if outstanding. Ford's owner notice states this recall service has no expiration date. If the updated system detects a dropping gate, it can close it under power with a rapid warning chime. Keep clear of a gate that will not remain open and have the support fault inspected. Confirm any separate strut repair and coverage with the dealer.

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Community Reported
High ConfidenceVerifiedReviewed Oct 2026

The sheet metal that supports the folding third-row seat latch strikers is mounted to the rear wheel wells, where it is directly exposed to road salt spray. On 2004-2007 Freestar and Monterey vans built March 24, 2003 through November 7, 2006 this bracket corrodes and structurally degrades, so the third-row seat may not fully latch into its seating position. In a rear impact an unlatched seat can move, raising injury risk to the occupants in it. Ford limited the campaign to salt-belt registration: CT, DE, IL, IN, IA, ME, MD, MA, MI, MN, MO, NH, NJ, NY, OH, PA, RI, VT, WV, WI and DC — roughly 196,500 vehicles. A van that has spent its life in one of those states is in scope even if it now lives elsewhere.

Common Symptoms

  • Third-row seat will not latch fully upright
  • Seat rocks or shifts when pushed from behind
  • Visible rust or flaking metal at the striker mounts on the rear wheel wells
  • Latch clicks but releases under load

How to Fix

Free recall remedy: dealers install new third-row seat latch striker mounting brackets at no charge under Ford campaign 13S01. Check the VIN against the NHTSA recall lookup — many of these vans changed hands before the 2013 notice reached the current owner. Verify by folding the third row up and confirming both strikers pull fully into latch; a seat that rocks or will not click home is the tell.

Typical repair cost:$0 - $0

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

Ford bulletin 06-14-10 covers certain 2004–2007 Freestars built before June 22, 2006 with driveability symptoms associated with water entering the PCM, connector or transaxle. Actual water damage must be established; rain correlation or several fault codes alone does not distinguish this from other engine or transmission faults.

This issue also affects: Ford Bronco, Ford Bronco Sport, Ford Edge

Common Symptoms

  • Engine sputters, loses power or stalls
  • Check engine light with multiple unrelated stored codes
  • Harsh or delayed shifts, delayed engagement
  • No reverse engagement
  • Rough idle and misfire
  • Engine overheat indication

How to Fix

Have a qualified technician confirm the affected component and consult the latest applicable Ford instructions, including any later PCM guidance. Repair the verified ingress path and assess connector, circuit and module damage before replacement. Investigate transaxle water contamination separately. Use a replacement PCM only when required, matched to the vehicle's hardware/calibration and programmed with the necessary security procedures.

Find a nearby Ford repair shop in Google Maps ↗

Call to confirm they can assess your vehicle and perform the stated work. Search results do not confirm qualification, eligibility or coverage.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Mintt VIN-programmed 2004 Freestar 3.9L PCM
    $190

    2004 Ford Freestar 3.9L only; choose this branch only after water damage is confirmed and the cowl leak is permanently repaired.

    Mintt
  • Flagship One 4F2A-12A650-GF VIN-programmed 2004 Freestar 4.2L PCM with keys
    $265

    Do not use for other 4.2L calibration codes or later years; provide VIN and repair the leak first.

    Flagship One

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

Freestar instrument clusters fail internally from cold or cracked solder joints on the circuit board. Symptoms range from the odometer/trip display going blank while the rest of the cluster still works, to gauges that flutter, drop out intermittently, or go dead entirely, to backlighting failures. The diagnostic tell that separates this from a wiring or sensor fault is mechanical: owners report that pulling the bottom of the cluster forward flexes the board and brings the display back, and pushing it home kills it again. A whole rebuild industry exists specifically for the 2004-2008 Freestar cluster, which is itself evidence of how routine the failure is. Note that a speedometer and odometer showing only dashes points instead at the vehicle speed sensor or its wiring, not the cluster.

Common Symptoms

  • Odometer or message center display goes blank
  • Gauges flutter or drop out intermittently
  • Display returns when the cluster is pressed or flexed
  • Dim or dead cluster backlighting
  • All gauges dead at once

How to Fix

Rule out the fuse and vehicle-speed input, then verify the intermittent cluster fault. Repairing the original cluster preserves mileage and avoids replacement programming.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Module Master 2004-2007 Freestar instrument-cluster rebuild
    $150

    2004-2007 Ford Freestar original cluster; verify the cluster matches the product photo and listed part-number family before sending it in.

    Module Master

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$120 - $500

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

On early-build Freestar and Monterey minivans the power steering low-pressure return line may not have been fully seated where it attaches to the rack and pinion steering gear. An incompletely seated line can back out and dump power steering fluid onto the hot exhaust, producing smoke and a possible under-hood fire. About 24,000 vehicles were covered. This is an assembly defect on the earliest units, not the general age-related power steering hose seepage that shows up on high-mileage examples.

Common Symptoms

  • Burning fluid smell or smoke from the engine bay
  • Power steering fluid reservoir dropping
  • Reddish fluid on the ground under the front of the van
  • Whine or heaviness at the steering wheel from low fluid

How to Fix

Free recall remedy: under Ford campaign 03S09 dealers inspect the low-pressure line and reseat it properly at the steering gear at no charge. Owner notification began November 10, 2003. On any Freestar, a fluid smell or smoke after a hard steering input should be treated as a leak onto the exhaust and inspected immediately rather than topped off.

Typical repair cost:$0 - $250

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

Ford TSB 07-1-2 (01/22/07) documents a leak at the power steering return line, near the cooler, on some 2004-2007 Freestar and Monterey vans. The concern exists only in extreme cold climates, -4F (-20C) and colder, and the bulletin applies only to vehicles used in the northern U.S. and Canada at those temperatures. This is distinct from the 03V457000 recall in which the low-pressure line came unseated at the rack.

Common Symptoms

  • Power steering fluid leak that appears only in very cold weather
  • Repeatedly low power steering fluid
  • Fluid on the ground under the front of the van

How to Fix

Ford TSB 07-1-2 addresses return-line leakage near the cooler on specified 2004–2007 Freestar vehicles used in Northern U.S./Canadian temperatures of -4°F (-20°C) or colder. Have a qualified repairer confirm the source and follow the complete bulletin: return-line replacement, the additional clamp, and the specified system flush and fluid refill. Confirm current approved parts/fluid and warranty eligibility for the VIN; this bulletin is not a safety recall. Separately, the low-pressure-line seating recall 03V457 applies to certain 2004 vehicles and should be checked with Ford.

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Community Reported
Medium ConfidenceVerifiedReviewed Oct 2026

The Freestar inherited many of the Windstar transmission problems. The torque converter develops shudder during light acceleration, and the transmission can fail completely with forward clutch pack burn-up.

This issue also affects: Ford Aerostar, Ford Bronco, Ford Crown Victoria

Common Symptoms

  • Shuddering at 40-60 mph
  • Harsh shifts
  • Slipping
  • Transmission warning light

How to Fix

Typical repair cost:$1,500 - $3,500

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Community Reported
Medium Confidence

The Freestar uses Ford's differential pressure feedback EGR system, and it fails in a well-known pattern. The DPFE (EGR pressure feedback) sensor loses accuracy when its diaphragm weakens or moisture contaminates it, so the PCM commands more vacuum to the EGR valve and the engine runs poorly. Separately, the EGR passages under the plastic upper intake carbon up and physically restrict flow. The original DPFE hoses are a high-temperature type that crack or collapse internally from thermal cycling, which produces the same code. Because there are three independent causes, owners commonly replace one part, clear P0401, and have it return within weeks — this is the single most repeated repair loop on these vans.

This issue also affects: Ford Bronco, Ford Bronco Sport, Ford E-Series

Common Symptoms

  • Check engine light with P0401
  • Rough idle or stumble at light throttle
  • Hesitation on acceleration
  • Failed state emissions test
  • Repeat return of the same code after a sensor replacement

How to Fix

Test DPFE voltage, inspect both high-temperature hoses, test the EVR solenoid and clean the intake EGR passages before ordering. The exact sensor, regulator and hose branches could not all be verified as a current purchasable fitment set, so no partial parts-swap link is approved.

Typical repair cost:$120 - $500

Research This Issue

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

Freestar owners report the ABS warning light coming on — typically after a corner — and staying on, which on this van also disables cruise control because the module drops out of the system. On vans with rear drum brakes, the rear wheel speed sensors sit where they collect metallic filings shed by the brake shoes; the accumulated ferrous debris bridges the gap to the tone ring and corrupts the speed signal. A related complaint is ABS activating at very low speed on dry pavement, which is the module reacting to a dropped-out signal from one wheel rather than to actual lock-up. A cracked or missing-tooth tone ring produces the same signature, as does a worn wheel bearing that lets the sensor gap open up.

This issue also affects: Ford Excursion, Ford Explorer, Ford Five Hundred

Common Symptoms

  • ABS light comes on, often after turning a corner, and will not go out
  • Cruise control inoperative while the ABS light is on
  • ABS activating at low speed on dry pavement
  • Brake pedal pulsing during normal stops
  • Fault clears on restart then returns

How to Fix

Read the ABS code, clean the identified rear sensor, bore and tone ring, then inspect the ring and hub bearing. Do not link a wheel sensor or hub until cleaning and mechanical inspection identify the failed branch.

Typical repair cost:$0 - $400

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Community Reported
Low ConfidenceVerifiedReviewed Aug 2026

The blend door actuator fails, causing the HVAC to blow only hot or only cold air regardless of temperature setting. A clicking noise behind the dash is the early warning sign.

Common Symptoms

  • Stuck on hot or cold air
  • Clicking behind dashboard
  • Temperature control unresponsive
  • Different temp from each vent

How to Fix

Replace the blend door actuator. Access requires removing part of the lower dash panel. The actuator is a small electric motor unit that clips onto the blend door shaft.

Typical repair cost:$50 - $250

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Community Reported
Medium Confidence

The fuel gauge on the Freestar reads erratically, sticks at one level, or pegs empty because the resistor card in the in-tank fuel level sender — part of the fuel pump module assembly — becomes contaminated by sulfur compounds from the gasoline. The sulfur deposits foul the contact track so the float's position no longer translates into a correct resistance, and the cluster shows nonsense. Owners run out of fuel with the needle showing a quarter tank. It is a fuel-system component failure, not a cluster failure, and replacing the instrument cluster does not fix it.

Common Symptoms

  • Fuel gauge stuck at full or at empty
  • Needle jumps erratically while driving
  • Low fuel light on with a nearly full tank
  • Running out of fuel with fuel indicated remaining

How to Fix

Try the documented detergent-cleaning route first. If three treated tanks do not restore a stable gauge, test the sender circuit and replace the confirmed sender/module branch rather than assuming the fuel pump failed.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Chevron Techron Concentrate Plus complete fuel-system cleaner, 20 oz
    $17

    Gasoline-engine first-step cleaner named by the repair.

    AutoZone
  • Genuine Ford 1F2Z-9A299-AA fuel-tank sender assembly
    $37

    2004-2005 Ford Freestar 3.9L or 4.2L with AX4N, after sender-circuit diagnosis. Does not cover 2006-2007; that OEM sender is discontinued and is intentionally not linked.

    FordPartsGiant

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$30 - $800

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Community Reported
Low ConfidenceVerifiedReviewed Aug 2026

The Freestar carries two evaporators — one in the dash and one in the rear unit — plus a long refrigerant run down the body to serve the rear. Two failures dominate: the rear expansion valve sticks and stops regulating refrigerant flow through the rear evaporator core, and the long rear lines, their O-rings and the rear core itself leak refrigerant. The signature complaint is front A/C blowing cold while the rear blows warm, with the rear feed line hot to the touch. This is a distinct failure from the dash blend door actuator problem that is already documented on this van; here the refrigerant side, not the air-distribution side, is at fault.

Common Symptoms

  • Front A/C cold but rear A/C blows warm
  • Rear refrigerant line hot to the touch
  • System loses charge over a season
  • Oily residue at rear line connections
  • Weak rear airflow

How to Fix

Use gauge readings and line temperature to distinguish a restriction from an O-ring, line or evaporator leak. Replace this valve only when the rear expansion valve is the confirmed restriction, then evacuate and recharge professionally.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Ford YF2Z-19849-AA auxiliary/rear evaporator expansion valve
    $24

    The live listing identifies the exact Ford part number; confirm VIN and rear-HVAC equipment before ordering.

    eBay

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$250 - $1,200

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Community Reported
Low ConfidenceVerifiedReviewed Aug 2026

The Freestar's power sliding doors jam and refuse to open either electrically or manually, often opening only a fraction of an inch before binding. A cause repeatedly identified by owners on the driver's side is the fuel filler door interlock: a cable and plastic lever tell the sliding door when the fuel door is open, so the door cannot swing into the fuel nozzle. When the plastic lever at the far end of that cable breaks, the system permanently believes the fuel door is open and locks the sliding door out. The other common cause is the door latch actuator or the door control module itself, where the door works manually but not from the switches. Owners report dealers misdiagnosing this as a motor failure.

Common Symptoms

  • Power sliding door will not open electrically or manually
  • Door opens only a half inch then binds
  • Door works manually but not from the switch
  • Door reverses or chimes and stops partway
  • Latch releases but the door will not move

How to Fix

Inspect the driver-side fuel-door interlock cable and plastic lever before any electrical parts. If the door works manually, scan and test the switch, harness and actuator; free and lubricate the tracks and rollers. No exact purchasable interlock repair part was verified.

Typical repair cost:$100 - $900

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Community Reported
Low ConfidenceVerifiedReviewed Aug 2026
Campaign #06E05600013/06/2006

STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.

Campaign #03V45700006/11/2003

WHEELS:HUB

CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB.

Campaign #04V44600013/09/2004

+ 1 more recalls. Check all on NHTSA.gov

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

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Recall 06V069 / Ford 06S42 applies to certain 2005–2006 Freestar vans with the power-liftgate option, built through December 13, 2005. After powered opening, the original system disengages its motor; a failed support strut can then allow the gate to fall and injure someone beneat… Severity: high.

What is the 2004-2007 Ford Freestar Torque Converter Shudder and Transmission Failure?

The Freestar inherited many of the Windstar transmission problems. The torque converter develops shudder during light acceleration, and the transmission can fail completely with forward clutch pack burn-up. Repairs typically run $1,500-$3,500. Severity: high.

What is the 2004-2007 Ford Freestar Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10)?

Ford bulletin 06-14-10 covers certain 2004–2007 Freestars built before June 22, 2006 with driveability symptoms associated with water entering the PCM, connector or transaxle. Actual water damage must be established; rain correlation or several fault codes alone does not distingu… Severity: high.

What is the 2004 Ford Freestar Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000)?

A batch of 2004 Freestar (and Mercury Monterey) minivans left the plant with front wheel hub assemblies that were not heat treated to specification. The under-treated hubs develop small fatigue cracks that propagate under normal load. If a crack runs to completion the wheel can s… Repairs typically run $250-$600. Severity: high.

What is the 2004 Ford Freestar Power Steering Low-Pressure Line Unseated at the Rack and Pinion (Recall 03S09 / 03V457000)?

On early-build Freestar and Monterey minivans the power steering low-pressure return line may not have been fully seated where it attaches to the rack and pinion steering gear. An incompletely seated line can back out and dump power steering fluid onto the hot exhaust, producing… Repairs typically run $0-$250. Severity: high.

What is the 2004-2007 Ford Freestar Rear Axle Trailing Arm Bushing Deterioration?

The Freestar's rear twist-beam axle trailing arm bushings crack and deteriorate, causing the rear end to feel loose and unstable. Worn bushings allow the rear axle to shift, causing poor alignment, inner tire wear, and a wandering feeling at highway speed. Repairs typically run $200-$600. Severity: medium.

What is the 2004-2007 Ford Freestar Third-Row Stowable Seat Latch Striker Bracket Corrosion (Recall 13S01 / 13V081000)?

The sheet metal that supports the folding third-row seat latch strikers is mounted to the rear wheel wells, where it is directly exposed to road salt spray. On 2004-2007 Freestar and Monterey vans built March 24, 2003 through November 7, 2006 this bracket corrodes and structurall… Repairs typically run $0-$0. Severity: medium.

What is the 2004-2007 Ford Freestar Power Steering Return Hose Leak Near the Cooler in Extreme Cold (TSB 07-1-2)?

Ford TSB 07-1-2 (01/22/07) documents a leak at the power steering return line, near the cooler, on some 2004-2007 Freestar and Monterey vans. The concern exists only in extreme cold climates, -4F (-20C) and colder, and the bulletin applies only to vehicles used in the northern U. Severity: medium.

What is the 2004-2007 Ford Freestar DPFE Sensor and Clogged EGR Passages Causing P0401 Insufficient EGR Flow?

The Freestar uses Ford's differential pressure feedback EGR system, and it fails in a well-known pattern. The DPFE (EGR pressure feedback) sensor loses accuracy when its diaphragm weakens or moisture contaminates it, so the PCM commands more vacuum to the EGR valve and the engine… Repairs typically run $120-$500. Severity: medium.

What is the 2004-2007 Ford Freestar ABS Light and Unwanted ABS Activation from Brake-Dust-Fouled Rear Wheel Speed Sensors?

Freestar owners report the ABS warning light coming on — typically after a corner — and staying on, which on this van also disables cruise control because the module drops out of the system. On vans with rear drum brakes, the rear wheel speed sensors sit where they collect metall… Repairs typically run $0-$400. Severity: medium.

What is the 2004-2007 Ford Freestar Rear Wheel Hub and Bearing Assembly Growl and Failure?

Separate from the 2004 recall on front hubs, the Freestar's rear hub/bearing assemblies wear out as a routine high-mileage failure across all four model years. Owners describe a speed-dependent hum or growl felt through the seats rather than the steering wheel, which is the givea… Repairs typically run $200-$500. Severity: medium.

What is the 2004-2007 Ford Freestar HVAC Blend Door Actuator Failure?

The blend door actuator fails, causing the HVAC to blow only hot or only cold air regardless of temperature setting. A clicking noise behind the dash is the early warning sign. Repairs typically run $50-$250. Severity: low.

What is the 2004-2007 Ford Freestar Fuel Level Sender Card Contamination Causing a Stuck or Erratic Fuel Gauge?

The fuel gauge on the Freestar reads erratically, sticks at one level, or pegs empty because the resistor card in the in-tank fuel level sender — part of the fuel pump module assembly — becomes contaminated by sulfur compounds from the gasoline. The sulfur deposits foul the conta… Repairs typically run $30-$800. Severity: low.

What is the 2004-2007 Ford Freestar Instrument Cluster Cold Solder Joints Causing Dead Gauges and Odometer Blackout?

Freestar instrument clusters fail internally from cold or cracked solder joints on the circuit board. Symptoms range from the odometer/trip display going blank while the rest of the cluster still works, to gauges that flutter, drop out intermittently, or go dead entirely, to back… Repairs typically run $120-$500. Severity: low.

What is the 2004-2007 Ford Freestar Rear A/C Expansion Valve Sticking and Rear Evaporator Circuit Leaks?

The Freestar carries two evaporators — one in the dash and one in the rear unit — plus a long refrigerant run down the body to serve the rear. Two failures dominate: the rear expansion valve sticks and stops regulating refrigerant flow through the rear evaporator core, and the lo… Repairs typically run $250-$1,200. Severity: low.

What is the 2004-2007 Ford Freestar Power Sliding Door Jams Shut — Fuel Filler Door Interlock Cable and Latch Failure?

The Freestar's power sliding doors jam and refuse to open either electrically or manually, often opening only a fraction of an inch before binding. A cause repeatedly identified by owners on the driver's side is the fuel filler door interlock: a cable and plastic lever tell the s… Repairs typically run $100-$900. Severity: low.