Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford Freestar owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
Car history: the transaxle light has gone before when we travel through vt mountains, but turning off the engine and letting it sit, and restarting it, the light would go off. Upon getting home safety, our mechanics didn't find anything to repair and so left it be, and would only sometimes see it when we traveled through the vt mountains, a few times a year. All recall repairs were up to date. There were no other symptoms. Incident: as we nearing the top of a mountain, the transaxle light came on. Unlike the other times, the transmission suddenly failed to be in the correct gear, so unlike the other times, we were very concerned. We pulled over immediately, and as we reached the shoulder smoke began pouring out of the vents. …
Ford is not honoring 13V081000 for the third row seat striker problems. Our van which is operated in the kansas city metropolitan area, which heavily salts the roads is having the corrosion problem. Just this weekend we were traveling with all seats occupied when the inner fender well on the rear passenger side broke through with the seat striker mounting bracket hitting the sidewall of the rear tire. Fortunately at the time we were not driving at high speeds and were able to remove the seat occupants and return home safely. The design of this seat striker plate is flawed as there is a reinforcing plate on the inner side of the fender well that results in entrapment of moisture and dirt. This bad design combined with the weight of three people occupying the seat results in stressing of the fender well material. …
First crack in u shaped steel channel noticed when I took this van in for other recall repairs at yucca valley Ford . They notified me and I had it welded . A few months later crack was back had it rewelded and gussets added to restrengthen both sides. Lasted six months till I took to tire shop to have front end aligned and two new tires put on. Left next day for gig broke one mile from home just past the weld. This van has always been a california car to my knowledge. No rust. Same rear axel as windstar. Bad design. Van is heavy little [redacted] steel channel to hold all that weight is stupid. Couldn't believe it was built that way. How come no recall for same axel design on Freestar. People apt to die from this stupid design.
Tl* the contact owns a 2004 Ford Freestar. While reversing into the garage, the vehicle failed to go forward or backward. The contact noticed a pile of rust on the ground and realized that the rear of the vehicle was entirely corroded. The vehicle was taken to liberty Ford of maple heights (5500 warrensville center rd, maple heights, oh 44137, [phone]) where it was diagnosed that the third row seat latch striker mounting brackets were corroded through and needed to be replaced. The vehicle was not repaired. The VIN was included in NHTSA campaign number: 13V081000 (seats). The manufacturer was notified of the failure and did not assist. The approximate failure mileage was 75,000.
Tl* the contact owns a 2004 Ford Freestar. When the vehicle was taken to an independent mechanic for an inspection, the vehicle failed the inspection due to excessive corrosion of the front frame. The contact called l. B. Smith Ford-Lincoln, inc. At [phone] (located at 1100 market st, lemoyne, pa 17043) where it was diagnosed that the frame needed to be replaced. The contact took the vehicle to two different independent mechanics to obtain some estimates. The vehicle was not repaired. The manufacturer stated that there was no recall and referred the contact to NHTSA. The failure mileage was approximately 118,000.
The 3rd seat hooks rusted out leaving and unstable passenger seat and body structure issues that are identical to the recall #13s01but due to the vehicle not being in a "saltbelt" state, it was not included in the recall even though it is pretty clear that kansas and nebraska use sale abundantly on the roads. I was told by Ford that my specific can was not included in the recall because is was manufactured differently than the 100,000 that were included in the recall so it should not have the same problem which it now has. I put my four kids in this van and now it is not structural stable for them.
Tl* the contact owns a 2004 Ford Freestar. While the vehicle was undergoing routine maintenance by an independent mechanic, the contact was informed that the control arm was protruding through the frame and created a hole. In addition, the check engine indicator illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and did not assist. The failure mileage was approximately 212,000. Consumer stated transmission just started to slip and makes a thud sometimes slips bad. Consumer has changed the transmission oil and filters.
Tl* the contact owns a 2004 Ford Freestar. Upon inspection, it was discovered that the carpet in the rear rows of the vehicle become wet and soaked. Upon inspection, it was discovered that the rear passenger seat anchor latch was loose. Months later, the driver noticed a grinding type noise when turning the vehicle. Upon inspection, it was discovered that the same failure had occurred on the driver's side. The failure was not diagnosed or repaired. The local dealer was not notified. The manufacturer was notified, but no assistance was offered. The failure mileage was 135,000.
Tl* the contact owns a 2004 Ford Freestar. The contact mentioned that the vehicle was once serviced under NHTSA campaign number: 13V081000 (seats). While observing the vehicle, it was noticed that the rear wheel well was severely corroded. The vehicle was taken to a dealer where it was diagnosed that the third row seat latch striker mounting bracket was corroded and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and stated that the vehicle was no longer under warranty. The failure mileage was 125,000.
NHTSA investigations
Stabilus Rear Liftgate Struts Failing
Please see the attached closing resume summary.It has been attached to this document as a PDF.
Body complaints in other Freestar years
Frequently asked questions
How common are body problems on the 2004 Ford Freestar?
NHTSA has 94 complaints about the body & structure of the 2004 Ford Freestar, 8% of the model year's 1,227 complaints. The component named most often is body (62 mentions).
Is there a recall for 2004 Ford Freestar body problems?
No. NHTSA lists no body & structure recall for the 2004 Ford Freestar, though it has 4 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford Freestar body problems start?
Half of the complaints with a recorded mileage happened before about 115,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 3 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
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.