Most common 2004 Ford Freestar problems
Share of the 1,227 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford Freestar complaints by model year
Best Freestar years: 2007, 2006. Years to avoid: 2004, 2005. Compare all years →
2004 Ford Freestar recalls (4)
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,…
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.
Power train › Automatic transmission › Torque converter
Ford is recalling certain model year 2004 and 2005 Ford freestar and Mercury monterey vehicles. The torque converter output shaft May fail.
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.
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.
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.
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.
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.
NHTSA defect investigations
Federal safety investigators have looked into 8 possible defects involving the 2004 Ford Freestar:
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 reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints…
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 jack screw is located (bends at mid-point).
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 circuit board became wet or which of the connector pins shorted out.In addition to causing an engine…
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 103 complaints experienced a loss of motive power but the specific internal failure cause within the…
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 states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia,…
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 containing a pump shaft spline that did not consistently meet the specified heat treatment…
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 Ford Freestar minivan due to water entering the PCM.Part 557 of Title 49 of the Code of Federal…
What 2004 Ford Freestar owners say
Transmission & drivetrain all 851 →
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.
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 & cooling all 118 →
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.
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.
Electrical system all 118 →
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.
This vehicle I received numerous recalls and had many problems with this vehicle. Major electrical problems. When it would rain and get car wash the electrical system would malfunction and cause engine not to run properly and check engine light would come on. In April of 2016 engine was malfunctioning and caused me to get in accident. This vehicle has since been impounded and loan company santander trying to bill me for remainder of loan and now causing major credit issues. I would like this to be covered by Ford/carmax for selling my family an unsafe vehicle which could have resulted in critical injury or worse.
2004 Ford Freestar engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 3.9L 6-cyl | 4-speed automatic | FWD | 15 / 21 / 18 |
| 4.2L 6-cyl | 4-speed automatic | FWD | 15 / 21 / 17 |
EPA ratings. Class: Minivan.
Frequently asked questions
Is the 2004 Ford Freestar a good car?
Based on 1,227 owner complaints filed with NHTSA, the 2004 Freestar rates avoid: 3.8× as many complaints as a typical year of the Freestar at the same age. It is one of the Freestar years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Ford Freestar?
The transmission & drivetrain — 851 complaints, 69% of all complaints for this model year, most often about automatic transmission. Next are the engine & cooling (118) and electrical system (118).
How many recalls does the 2004 Ford Freestar have?
There are 4 recalls for the 2004 Ford Freestar, the most recent from March 7, 2013 (seats). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford Freestar?
The best years by complaints, compared at the same age, are 2007 and 2006. Years to avoid or approach with caution: 2004 and 2005. See the full Ford Freestar years comparison.
At what mileage do 2004 Ford Freestar problems happen?
The median mileage reported in complaints is about 86,000 miles; 13% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.