2004 Ford Freestar
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Freestar › 2004
These records cover every 2004 Ford Freestar. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2004 Ford Freestar. Newest first.
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…
Risk and remedy
Risk
In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
Remedy
Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
Ford IS recalling certain model year 2004 and 2005 ford freestar and mercury monterey vehicles. the torque converter output shaft may fail.
Risk and remedy
Risk
This condition results in a sudden loss of motive power with no warning, increasing the risk of a crash.
Remedy
Ford will notify owners, and dealers will replace the torque converter free of charge. the safety recall began on august 9, 2012. owners may contact the ford motor company customer relationship center at 1-866-436-7332.
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…
Risk and remedy
Risk
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
Remedy
Ufi will notify owners and replace the filters free of charge. the recall began on august 4, 2006. owners may contact ufi filters USA at 800-230-5876.
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.
Risk and remedy
Risk
If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash.
Remedy
Dealers will replace the front hub, rotors, and wheel bearings. the recall began september 20, 2004. owners should contact ford at 1-800-392-3673.
On certain minivans, the power steering low-pressure line may not be fully seated at the rack and pinion steering gear.
Risk and remedy
Risk
If this line becomes disconnected, it may create the potential for fluid to come into contact with the exhaust system, which could result in smoke or fire.
Remedy
Dealers will inspect the power steering low-pressure line to ensure that it IS seated properly at the rack and pinion steering gear. owner notification began november 10, 2003. owners should contact ford at 1-800-392-3673.
Owner complaints
1,227 complaints16 involved a crash14 involved a fire21 injuries1 deaths
What owners report most
Latest complaints
- Power train
The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An independent mechanic diagnosed that the torque converter and the transmission needed to be…
The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An independent mechanic diagnosed that the torque converter and the transmission needed to be replaced. The contact related the failure to an unknown NHTSA Campaign Number; however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 104,000.
- Power train
Flashing! With gear around it and car will not operate correctly i.e. no power very slow acceleration and lacking ability to change gears.
- Engine · Power train
I have a 2004 Ford freestar van and I was driving down the road and I went to pass another vehicle and I push the gas and I heard some crunchy noise is and then nothing no power at all no gears nothing I was dead in the water so I had to get out of the van and push it to the side of the road didn't…
I have a 2004 Ford freestar van and I was driving down the road and I went to pass another vehicle and I push the gas and I heard some crunchy noise is and then nothing no power at all no gears nothing I was dead in the water so I had to get out of the van and push it to the side of the road didn't have reverse didn't have drive didn't have third second or first no gears at all the transmission failed me I could have been in a very bad accident and hurt it just came out of nowhere there was no signs of anything wrong with the van and then this happens.
- Power train
My son was driving down Rt 81 when the transmission stopped working Your vehicle was running fine but would not go had to drift off the highway she avoid getting hit I had to tow the van home we’re it’s still parked
- Power train
The contact owns a 2004 Ford Freestar. The contact stated that while driving at various speeds the vehicle would not properly accelerate and would hesitate to accelerate and the check engine warning light would remain illuminated. The vehicle was taken to the local mechanic who diagnosed that the…
The contact owns a 2004 Ford Freestar. The contact stated that while driving at various speeds the vehicle would not properly accelerate and would hesitate to accelerate and the check engine warning light would remain illuminated. The vehicle was taken to the local mechanic who diagnosed that the transmission torque converter was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were contacted and informed that the VIN was not included in the NHTSA Campaign Number: 12V006000(Power Train). The contact indicated that the vehicle had experienced that same failure listed in the recall. The VIN was not available. The failure mileage was 250,000.
- Engine
Conducía mi vehículo y la trasmisión quedó en neutro en una entrada y no pude estacionarme Y no volvió arrancar Solo coje la reversa I was driving my vehicle and the transmission was neutral in a driveway and I couldn't park And did not start again Just take the reverse
- Back over prevention › Warnings · Electrical system · Power train
The transmission is grinding and popping when shifting gears.Also it has started not moving when I shift it into drive and 3rd and 1st.When I drive it I have to put it in 1st gear and change up to drive and it grinds and pops when giving it gas to go.It comes to a crawl going up hills.Has a big…
The transmission is grinding and popping when shifting gears.Also it has started not moving when I shift it into drive and 3rd and 1st.When I drive it I have to put it in 1st gear and change up to drive and it grinds and pops when giving it gas to go.It comes to a crawl going up hills.Has a big loss of power.The trackshion control light comes on saying it's not working.The electrical is messing up the doors are opening up when they are not supposed to going down road.It tells me that different doors are open when there not keeping the lights on in the van running down the battery.
- Unknown or other
I just purchased the vehicle used and recently discovered there was a recall on these vehicles. The vehicle I purchased keeps stalling and is not getting any power. I’ve had the vehicle checked by the car lot and they say there is nothing wrong.. the vehicle died out on me already twice while I was driving.
- Power train
The contact owns a 2004 Ford Freestar. The contact stated while driving approximately 55 MPH, the vehicle started losing motive power. The contact depressed the accelerator and the vehicle continued to slow as the RPM was rising. The contact did not notice any warning lights illuminated. The…
The contact owns a 2004 Ford Freestar. The contact stated while driving approximately 55 MPH, the vehicle started losing motive power. The contact depressed the accelerator and the vehicle continued to slow as the RPM was rising. The contact did not notice any warning lights illuminated. The contact pulled safely off the road and turned the vehicle off. The vehicle was restarted however, failed to shift into higher gears while attempting to reach highway speeds. The contact drove the vehicle to her residence. The vehicle was not taken to be diagnosed or repaired. The contact researched online and found NHTSA Campaign Number: 12V006000 (Power Train) which she linked to the failure. The manufacturer had not been informed of the failure. The failure mileage was 158,000.
- Power train
Transmission slip , leaks , loosing ofpower, shakes from 45 mph to 55 mph , mechanic shop says it is the Torque Converter that is malfunction.
- Power train
the van has less than 49k miles on it and the reverse has not worked but it will drive forward. Others have had this issue as well.
- Engine
The contact owns a 2004 Ford Freestar. The contact stated while driving 35 MPH, the vehicle began to stall. The contact stated no warning light was illuminated. The contact was able to restart the vehicle and drive to his destination. The contact took the vehicle to an independent mechanic and was…
The contact owns a 2004 Ford Freestar. The contact stated while driving 35 MPH, the vehicle began to stall. The contact stated no warning light was illuminated. The contact was able to restart the vehicle and drive to his destination. The contact took the vehicle to an independent mechanic and was informed that the computer needed to be dried off. The vehicle was repaired but continued to experience failure. The vehicle was not diagnosed or repaired. A dealer was not contacted. The contact stated he had experienced the failure several times. The manufacturer had not been informed of the failure. The failure mileage was approximately 38,000.
- Seats
The contact owns a 2004 Ford Freestar. The contact stated that the third-row seat floorboard was corroded with several holes. The TPMS warning light was illuminated. The contact received notification of NHTSA campaign number: 13V081000 (Seats) however, the part to do the recall was unavailable. The…
The contact owns a 2004 Ford Freestar. The contact stated that the third-row seat floorboard was corroded with several holes. The TPMS warning light was illuminated. The contact received notification of NHTSA campaign number: 13V081000 (Seats) however, the part to do the recall was unavailable. The vehicle was taken to the local dealer who declined to repair the vehicle due to part availability issues. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure. The failure mileage was approximately 150,000. Parts distribution disconnect. (RECALL REMEDY INCIDENT) TS
- Power train
TL* the contact owns a 2004 ford freestar. The contact stated that when placing the vehicle into any gear, the vehicle would stall without warning. The contact called all american ford of hackensack (520 river st, hackensack, nj 07601) where he was given a diagnostic fee. Upon investigation, the…
TL* the contact owns a 2004 ford freestar. The contact stated that when placing the vehicle into any gear, the vehicle would stall without warning. The contact called all american ford of hackensack (520 river st, hackensack, nj 07601) where he was given a diagnostic fee. Upon investigation, the contact discovered nhtsa campaign number: 12v006000 (power train) which he linked to the failure. The manufacturer was notified of the failure and informed him that the vin was not included in the recall. The vehicle was not repaired. The failure mileage was approximately 100,000.
- Electrical system
I read the recalls for 2004 ford free star transmissions and my van without warning just quit working in the middle of the road while I was driving. I could get it to start back up for a second to move it to the side of the road, but it wouldn't start after that.
- Electrical system · Power train · Steering
Pcm has issues do to moisture which affects electrical slipping gears ABS sensor problem power steering issues and tcm and this vehicle has all safety problems according to recalls none of it was fixed because ford says your vin number IS not on list.
- Unknown or other
I just came across this website and wish I wrote this a year ago because I would have made a complaint then. I have had many issues with the lights flickering, coming on automatically when it rains, my interior lights staying on and actually catching fire because it had gotten so hot. My radio used…
I just came across this website and wish I wrote this a year ago because I would have made a complaint then. I have had many issues with the lights flickering, coming on automatically when it rains, my interior lights staying on and actually catching fire because it had gotten so hot. My radio used to turn on by itself or not turn on at all, which has now been replaced. My van has literally died on me while driving more often at times when I'm making a turn or slightly moving my steering wheel. Has almost caused a few accidents because it shuts off without warning. My van will usually have a higher rpm when it's running in park or with foot on break(waiting at a red light). Then suddenly the rpms drop and fluctuate high and low and shut the engine off. My transmission IS also starting to fail by not shifting properly. Usually into second gear. The indicator lamp light flashes with means error with the transmission. That IS most likely due to the power train automatic transmission torque converter getting wet or it IS powertrain automatic transmission. Also have issues with my my power steering the wheel knocks and sorta locks up at times , fluids have been checked and were perfect. I believe that it's associated with the steering hydraulic system failure.
- Seats · Structure › Body
The part that has the clip for back seat fell out and now there IS a 5 by 5 inch hole going into the wheel well and the seat has nothing to clip onto and be secure, this was recalled in this model
- Power train
The vehicle was in motion on a highway at a speed of 55 mph when it had instant transmission failure. Pulled over to the side of the road. Vehicle wouldn/t move in any direction or gear. Transmission was in proper fluid level range.
- Power train · Service brakes · Vehicle speed control
Driving down rd n it felt as if someone was pushing break while I was smashing gas pedal . Lost all fire to car wouldn't go no where. I was on a country rd going uphill. It spots n sputter n jerks real hard going up hill like my transmission going bad but motor sounds good so I have no clue..
- Power train
I was driving down the highway at approximately 45 miles per hour when all of a sudden my rpms shot up but I had no acceleration it did this without warning I managed to get over to the side of the road, and I was going to check transmission fluid but when I pulled the dipstick out fluid shot out…
I was driving down the highway at approximately 45 miles per hour when all of a sudden my rpms shot up but I had no acceleration it did this without warning I managed to get over to the side of the road, and I was going to check transmission fluid but when I pulled the dipstick out fluid shot out the dipstick hole. I was able to walk to a store & buy transmission fluid that I added. I waited a bit then tried drive, reverse, low gear, but nothing. Had to call a tow truck
- Engine · Power train · Unknown or other
Torque convertor defective in similar ford freestar models eddy's ford dealership sold recall vehicle as IS against state & federal laws and lied to disabled veterans about replacing the defective torque converter after discovery of recall caused piston hole engine block and transmission damage cutting out near dangerous bridge intersection.
- Steering
TL* the contact owns a 2004 ford freestar. The contact stated while driving at various speeds, the steering wheel vibrated and started pulling to the right. There was no warning light illuminated. The vehicle was taken to an independent mechanic and the contact was informed the subframe of the…
TL* the contact owns a 2004 ford freestar. The contact stated while driving at various speeds, the steering wheel vibrated and started pulling to the right. There was no warning light illuminated. The vehicle was taken to an independent mechanic and the contact was informed the subframe of the front end was fractured and that an alignment could not be performed. Ray price mt. Pocono ford located at (2971 pa-940, mt pocono, pa 18344), were made aware of the failure. The vehicle was not diagnosed nor repaired. The manufacturer was informed of failure. The failure mileage was 127,000.
- Power train
My fiance was driving to work when she heard a clicking noise then a loud bang come from the transmission, she lost all power, if she hadn't responded to the situation and turn immediately into a church driveway she would have been rear ended! the van was in motion driving southbound on 257th…
My fiance was driving to work when she heard a clicking noise then a loud bang come from the transmission, she lost all power, if she hadn't responded to the situation and turn immediately into a church driveway she would have been rear ended! the van was in motion driving southbound on 257th st in the city of gresham. I was just now researching the van and saw ford recalled 200,000 of this year's van dew to a faulty torque converter and other issues with the transmission
- Fuel/propulsion system · Power train · Wheels
I have spent so much money in this van that I would like to report these issues to you first it was the fuel filter and now it's the transmission I keep the maintenance up and things still go wrong
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Stabilus Rear Liftgate Struts Failing
Please see the attached closing resume summary.It has been attached to this document as a PDF.
- Corrosion of Third-Row Seat Attachment
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt…
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
- Corrosion of Third-Row Seat Attachment
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI…
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
- Service Jack Failure
The subject vehicles (SV) are all automatic transmission, front wheel drive vehicles with hand actuated mechanical park brakes. The investigation focused on allegations that the service jack failed and caused the vehicles to fall. The subject scissors-type jack appears to fail at the slotted hinge joints where the…
The subject vehicles (SV) are all automatic transmission, front wheel drive vehicles with hand actuated mechanical park brakes. The investigation focused on allegations that the service jack failed and caused the vehicles to fall. The subject scissors-type jack appears to fail at the slotted hinge joints where the jack screw is located (bends at mid-point). The failures occur while the jack is in use, and vehicle movement (forward or backward) is typically reported coincident with the failure. Ford reported that most MY 2003 Windstar and all MY 2006-2007 Freestar/Monterey also use the subject jack, an additional 223,246 vehicles.NHTSA has received six consumer complaints (VOQs) involving three injury incidents and a fatality.Ford reported 26 complaints for the SVs involving an additional 4 injuries. In the fatal incident, the van fell on a person working on the engine under the otherwise unsupported vehicle; ODI was unable to determine whether the vehicle was adequately chocked or the park brake was properly set. Reported injuries include a broken arm, head and hand injuries, arm and rib bruises, and muscle strains. NHTSA has received just one new report since opening this investigation. The complaint trend in ODI and Ford data is flat if not declining.Ford provides instructions and warnings in the owner's manual, on a placard placed with the jack, and on the jack itself. These instruct consumers to put the vehicle gear selector in Park, properly set the parking brake, chock the opposite wheel, use the jack only for changing a tire, loosen the lug nuts prior to jacking, and to not get under a vehicle supported by the jack only (NHTSA also recommends that jacks only be used for tire changing).In the VOQs, roughly half the consumers were using the jack for something other than tire changing, half had not chocked a wheel, and half had not properly set the parking brake. ODI notes that since the front wheels are drive wheels (with an open center differential) the Park gear cannot provide vehicle stability (longitudinally) when a front wheel is raised. All NHTSA complaints and most of the complaints to Ford involved failures while a front wheel was raised.In response to ODI's inquiry, Ford conducted testing on a 2004 Freestar. Ford's tests showed that when a front tire was raised the service jack held without failing under various scenarios except when a rocking force was applied and the parking brake was not properly set. Based on its testing and its analysis of field data, Ford concluded that the type of jack failure evidenced in this investigation (bending at mid-point) was likely caused by vehicle movement due to an improperly secured vehicle, or other misuse of the jack. Ford notes that rates in this investigation were similar to those in another investigation (EA91-049) which ODI closed. ODI also analyzed jack data for MY 2003 and newer vehicles to compare to the SV population. To assist with this analysis, ODI requested data from the jack manufacturer (actually its successor company) who provided limited data but did identify other models using the same design jack. ODI was unable to identify a significant difference in the incidence of jack failures (including those involving bending failures) between the SVs, other vehicles which used the same jack, or other vehicles where the jack type was unknown or different.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, investigation PE11-033 is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist and ODI reserves
- Engine Stalling
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the…
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
- Transmission Torque Converter Failure
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters…
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
- Torque converter output shaft failure
Odi has received 227 owner complaints alleging a sudden and unexpected loss of motive power due to an internal transmission failure in the subject vehicles.of those complaints, 124 can be attributed to the torque converter output shaft splines stripping causing a sudden loss of power to the drivetrain.the remaining…
Odi has received 227 owner complaints alleging a sudden and unexpected loss of motive power due to an internal transmission failure in the subject vehicles.of those complaints, 124 can be attributed to the torque converter output shaft splines stripping causing a sudden loss of power to the drivetrain.the remaining 103 complaints experienced a loss of motive power but the specific internal failure cause within the transmission IS not known.odi has upgraded the investigation to an engineering analysis (ea09-016) to continue its assessment of the scope, frequency and safety-related consequences of the alleged defect.
- Engine stalling
On May 6, 2009, NHTSA received a request for a hearing through Title 49 of the United States Code, Chapter 301, Motor Vehicle Safety, Part 557. the request was in reference to vehicle owner complaint, 10266067, filed with NHTSA on April 20, 2009, which described a problem with engine stall in a model year (MY) 2004…
On May 6, 2009, NHTSA received a request for a hearing through Title 49 of the United States Code, Chapter 301, Motor Vehicle Safety, Part 557. the request was in reference to vehicle owner complaint, 10266067, filed with NHTSA on April 20, 2009, which described a problem with engine stall in a model year (MY) 2004 Ford Freestar minivan due to water entering the PCM.Part 557 of Title 49 of the Code of Federal Regulations establishes procedures for holding a hearing to determine whether a manufacturer has reasonably met its obligation to notify owners of a safety related defect.Because a safety related defect has not been determined regarding the alleged defect in MY 2004 Ford Freestar vehicles, the Office of Defects Investigation interpreted the request as a defect petition under Part 552 of Title 49 of the Code of Federal Regulations.In response to the Information Request letter sent by ODI for DP09-004, Ford indicated that a variety of symptoms could result from water intrusion into the PCM, including no start, rough idle, engine misfire, transmission performance degradation, lack of transmission engagement, illumination of the check engine light, and engine stall while driving or parked.Ford stated that it believes that the overall complaint rate for engine stalling is low and comparable to other similar stalling related investigations that the agency has recently closed.Ford stated that the water entry into the PCM is a customer satisfaction issue.ODI has granted DP09-004 and opened a Preliminary Evaluation, PE10-033, to further assess the scope, frequency and potential safety-related consequences of the alleged defect.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10205034Safety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers - requests for recall service action
- 10183770For 2004-2007 Freestar or Monterey vehicles Safety Recall 13S01 has been issued for vehicles that are operated in high corrosion areas for an extended period, where the sheet metal that supports the folding 3rd row seat latch strikers could experience corrosion and may compromise the mounting point for the forward portion of the 3rd row seat. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the front of the seat when in its seating position. If corrosion is severe, the seat latch strikers may become detached from the vehicle. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected.
- 10109070The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
- 10058103Ford/mercury: safety recall regarding sheet metal support for folding 3RD row seat latch strikers can experience corrosion and will compromise mounting point causing seat to move. Model 2004-07 freestar, monterey.
- 10056468Ford/mercury: sheet metal supporting folding 3RD row seat latch strikers will experience corrosion and compromise mounting point for forward portion of 3RD row seat, if vehicle IS operated in high corrosion areas for extended period. Model 2004-2007 freestar, monterey.
- 10021907Advanced traction control system - short duration activation.
- 10021217Power steering hose leak near cooler extreme cold climate areas only -4 degrees and cooler.
- 10020701Advanced traction control system - duration activation.
- 10019067Rear climate control noises - service tip.
- 10018071Restraint control module diagnostic trouble code b2296 - service tip.
- 10017923Service wiring harness replacement guidelines - service tips.
- 10017893Traction control lamp - ABS lamp - ABS self activation with dtc c1288. Updated 11/8/07.
- 10017552A broken outer c/v joint on vehicles built before 5/1/2005.
- 10016816Steering wheel and or vehicle vibration-vehicles equipped with goodyear intergrity 16 inch tires only.
- 10016808Erratic fluid level reading on transaxle dipstick-leaks-4f50n, AX4N, AX4S transaxle.
- 10014704Steering wheel.
- 10014607Instrument cluster dtc u1262 and or u1135.
- 10014604Instrument cluster dtc u1130.
- 10014279Rear brake lining accelerated wear.
- 10014261Power sliding doors and power liftgate inoperative when using the overhead console and/or remote keyless entry transmitter open/close buttons - diagnostic trouble code (dtc) c1999.
- 10014138Safety belt retraction speed.
- 10014086General (pcm) power train control module programming procedures.
- 10014062Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10013417Traction control ABS and park brake lamp. Flicker flash illuminate.
- 10013405Traction control ABS and park brake lamp flicker flash illuminate.
- 10013404Access door wraped or breaking off from the underside of the steering wheel shrod.
- 100133903RD row seat strap breaking.
- 10013369General power train control module (pcm) programming procedures.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10012954Safety belt web stop button service.
- 10012947Maf diagnostic service tip - vehicles equipped with egr system module (esm).
- 100113363RD row seat strap breaking (strap used for stowing or accessing the rear seat).
- 10011172Noise from front wheel hub bearing. * ar
- 10011159Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 100111574F50n transaxle no 1-2 upshift and diagnositc trouble code p0732.
- 10010741Accelerated rear brake wear. Oasis.
- 10009328Front blower motor whistle noise.
- 10009321Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns.
- 10009320Diagnostic trouble code b1342 (restraints control module (rcm) fault. Update.
- 10009319Front door glass click/snap noise at the end of the upward glass position.
Every Ford Freestar model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.