Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
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).
Dt*: the contact stated the brake pedal went to the floor twice while attempting to stop. This occurred at 30 MPH. The first time, there was no damage. The dealership was unable to determine a problem, but replaced the master cylinder. The second time, while approaching an intersection, the contact depressed the brake pedal. The vehicle did not slow down; the vehicle was steered to the right over a curb into a parking lot. The vehicle did not slow down and crossed a three lane highway into another parking lot where the vehicle was stopped by shrubs. This caused a tire to blow out and minor damage to the bumper. The vehicle was towed to the dealership, but the dealership was unable to determine a problem.
Dt*: the contact stated in April 2005, the ABS and airbag lights illuminated. The vehicle was taken to the dealership. The codes were reset and the lights went off. Then, while driving 40 MPH on dry roads, a vehicle pulled out in front of the contact. The brake pedal was depressed, but the ABS did not activate. Upon impact, the airbags did not deploy. There was a police report taken at the scene. The vehicle was towed to an independent repair shop, where it was deemed a total loss. The contact was wearing a seat belt, but sustained a broken ankle and hand, a dislocated shoulder, and a concussion. The vehicle was not inspected to determine the problem with the airbags or antilock brakes.
Alpr system on telephone poles and police cars are attacking my vehicle. Already destroyed my ABS brake system module and now working on my starter motor, blower motor, speed control and etc. Some attacks cause loud base drum like thumping on my dashboard. Other attacks lock my gearshift lever in park, unlock my doors. Stop my speed control from working, and etc. These attacks have been ongoing for about 4 years. Along with these attacks, police cars frequently threaten me with head-on collisions. The thumping scares me when it occurs in heavy traffic and could cause an accident. These attacks occur in all modes of vehicle operation and when passing alpr telephone poles and police cars.
The indiana alpr tracking system causes electrical malfunctions including the ABS brake system and various other unknown malfunctions. The ABS module has failed on the subject vehicle and the alpr attacks continue. These alpr attacks are initiated by electrical apparatus on top of telephne poles and on police cars. These attacks can be heard by sudden unexpected loud thumping on my dashboard which could cause an accident in addition to the ABS brake system failure. These attacks occur both in motion and when stationary. The thumping is expecially surprising in traffic and could easily cause an accident. Plus, I do not have ABS protection on slick roads
The 2004 Freestar is shorting out all the sensors are shorting out u took it to be put on machine and it cane back with 17 sensors malfunction going on and it's the only vechele I own and I've googled the problem and I see 100000 other people are having the same problem what should I do I might be driving down the road and the vraje sensor is going and I can't stop I'm not rich I cantvgo buy another van please help me
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..
Last week, in order to prepare for a trip away I had my 2004 Ford Freestar serviced and got new tires, etc., and then the mechanic said I needed new brakes and rotors and spent $1,000.00 on parts and labor (including the tires). He showed me the rotors and explained how bad of shape they were in, there were deep grooves in them. At least feeling confident that all this work was completed and I was ready for my trip, off I went. Then all of a sudden driving at 70 MPH on the pa turnpike I realized the power had gone from the gas pedal and the van would not go forward. I quickly pulled to the side and turned vehicle off, then tried again, it would not go in drive or reverse or any lower gear. …
We own a 2004 Freestar that has had the transmission replaced in feb 2008 with less than 43,000 miles on it. In July 2008 we spend $450 on repairing part of the breaking system, and this week the van would not go into reverse and did not have any pull to it when it finally did after several attempts. Once I got out of the parking space, I got an estimate of a block and onto a busy highway, only to have the van stall on me, almost causing a wreck. The dealership and Ford paid for the transmission to be replaced, we paid for the caliper, drum, rotor, and break pad to be replaced on the front driver side brake. When having the van checked out this week, we were told yesterday that they did diagnostics on it, and the only thing that came back was a cam sensor and that there was probably moisture involved that would cause the stalling. …
Bought van in June 2007 nothing but problems since. Replaced battery within 2 months of purchase. Replace o2 sensors 3 times and need done again. Replaced transmission, radiator, EGR valve, brakes 4 times, tie rod 2 times, calibers 2 times, rotors 3 times, fuel line, you name it, we have had to fix it. Nothing but problems. We have spent close to 8K since feb 2008 on this vehicle and we can not get Ford to help us at all. Now the axles need replaced as well as sensors again. The dvd player quit working after 4 months, driver side heated seats quit working after 4 months. Back passenger door sometimes won't open or unlock and sometimes it won't close when you try to close it. This vehicle has put my family in serious harm and we almost got into major accident do to most of the issues ie transmission stalled on interstate and had no warning at all. Worst vehicle of all times. …
I was traveling on a busy road last Sunday. My van completely shut down with no warning. I had no power steering or power brakes and was almost rear-ended. Thank god I managed to get to the side of the road. I started it again and it happened again three more times. I had it towed to jim's auto service and they think it could be related to water leakage onto the computer. I called Ford to ask about this and they said that they knew nothing about this but I found information about this problem all over the internet. I asked them how could my mechanic know about this and they didn't?! They told me to take it to a Ford dealership. I am 60 years old and babysit my grandchildren full time and I am afraid to drive them in this vehicle! I also do not have the money for major repairs. …
Brake complaints in other Freestar years
Frequently asked questions
How common are brake problems on the 2004 Ford Freestar?
NHTSA has 59 complaints about the brakes of the 2004 Ford Freestar, 5% of the model year's 1,227 complaints. The component named most often is foundation components › disc › rotor (10 mentions).
Is there a recall for 2004 Ford Freestar brake problems?
No. NHTSA lists no brakes 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 brake problems start?
Half of the complaints with a recorded mileage happened before about 45,000 miles, and 28% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 0 fires and 1 injury to brakes 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.