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 Ignition Coil Pack Failure?

The coil-on-plug ignition coils on the 3.9L and 4.2L V6 engines fail frequently, causing misfires, rough running, and reduced fuel economy. Often one coil fails and the others follow shortly. Repairs typically run $150-$400. 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 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 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 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.

Ford · Known Issues

2004 Ford Freestar Problems: 16 Known Issues

2004 model year · 370+ owner reports · Updated August 2026

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According to Au7o's analysis of 370+ owner reports, the 2004 Ford Freestar has 16 documented known issues, with 5 rated critical. The most serious are AX4S Transmission Torque Converter Shudder and Failure ($200-$2,500 repair), Torque Converter Shudder and Transmission Failure ($1,500-$3,500 repair), Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000) ($250-$600 repair), Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10) ($300-$1,200 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 AX4S Transmission Torque Converter Shudder and Failure with 210 owner reports. Across all issues with published estimates, repair costs range from $30 to $3,500. DIY maintenance guides at au7o.io.

Frequently Asked Questions

What are the most common Ford Freestar problems?

According to Au7o's analysis of 370+ owner reports, the 2004 Ford Freestar has 16 documented issues. The most frequently reported are: AX4S Transmission Torque Converter Shudder and Failure, Torque Converter Shudder and Transmission Failure, Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000). Of these, 5 are rated critical and should be addressed promptly.

Is the Ford Freestar reliable?

The 2004 Ford Freestar has 16 known issues documented across 370+ owner reports. 5 issues are rated critical: AX4S Transmission Torque Converter Shudder and Failure and Torque Converter Shudder and Transmission Failure and Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000) and Water Intrusion into the PCM from the Cowl Grille Causing Stalling, Harsh Shifts and No Reverse (TSB 06-14-10) 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. The most critical issue, AX4S Transmission Torque Converter Shudder and Failure, typically costs $200-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2004-2007 Ford Freestar AX4S Transmission Torque Converter Shudder and Failure?

The Freestar's AX4S 4-speed automatic transmission develops torque converter shudder during light acceleration at 35-50 mph. The converter clutch lining disintegrates, contaminating the fluid with debris that damages the valve body and solenoids. Repairs typically run $200-$2,500. Severity: high.

All 16 Known Issues

Other Ford Models

Frequently Asked Questions

What are the most common Ford Freestar problems?

Is the Ford Freestar reliable?

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

What is the 2004-2007 Ford Freestar AX4S Transmission Torque Converter Shudder and Failure?

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

2004-2007 Ford Freestar: AX4S Transmission Torque Converter Shudder and Failure#

2004-2007 Ford Freestar: Torque Converter Shudder and Transmission Failure#

2004 Ford Freestar: Front Wheel Hub Cracking from Improper Heat Treatment (Recall 04S24 / 04V446000)#

2004-2007 Ford Freestar: Rear Axle Trailing Arm Bushing Deterioration#

2004-2007 Ford Freestar: Rear Wheel Hub and Bearing Assembly Growl and Failure#

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

2004-2007 Ford Freestar: Instrument Cluster Cold Solder Joints Causing Dead Gauges and Odometer Blackout#

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

2004-2007 Ford Freestar: Ignition Coil Pack Failure#

2004-2007 Ford Freestar: Third-Row Stowable Seat Latch Striker Bracket Corrosion (Recall 13S01 / 13V081000)#

2004-2007 Ford Freestar: ABS Light and Unwanted ABS Activation from Brake-Dust-Fouled Rear Wheel Speed Sensors#

2004-2007 Ford Freestar: DPFE Sensor and Clogged EGR Passages Causing P0401 Insufficient EGR Flow#

2004-2007 Ford Freestar: HVAC Blend Door Actuator Failure#

2004-2007 Ford Freestar: Fuel Level Sender Card Contamination Causing a Stuck or Erratic Fuel Gauge#

2004-2007 Ford Freestar: Rear A/C Expansion Valve Sticking and Rear Evaporator Circuit Leaks#

2004-2007 Ford Freestar: Power Sliding Door Jams Shut — Fuel Filler Door Interlock Cable and Latch Failure#

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

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)?

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