Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
Tl* the contact owns a 2004 Ford Freestar. While driving approximately 70 MPH and suddenly on an elevation, the vehicle shook, decelerated, and lost power without warning. The contact pulled into an independent mechanic's shop where the technician changed the fuel filter. The failure recurred a few days later. The check engine light illuminated. The vehicle was taken to another independent mechanic who did not diagnose the failure. The manufacturer was made aware of the failure and stated that there was no recall. The VIN was unknown. The vehicle was not repaired. The failure mileage was 87,000.
Tl* the contact owns a 2004 Ford Freestar. The contact stated that while parked, there was a strong odor of fuel outside of the vehicle. The entire fuel tank exhibited rust corrosion as a result fuel leaked from the outer part of the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 81,000.
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. …
Purchased used vehicle from marshall used cars in sacramento, ca, where reside currently. Purchased 05/2011, paid full no loan at time of purchase. Purchased add. Ext. Warranty which was 6months. From the dos til present date; I have paid, and was mislead in all the insurance covering major defects, owner(me) had came out of pocket paying for service to fix warranty parts. Now this is the current and serious issue. I am disabled, I have a disable child. My vehicle was reported under VIN to Ford corporate to notate for service to be check and worked on at local Ford dealer. Complained about multiple (4) issues. Dealership mislead me, and did not perform work. Only work they did was replace 1 recall 10/12. After recall service I (owner) recall manufac. Made claim, again and then went to dealer. I was turned away...and told to do normal maintenance before putting a service claim in. …
Just purchased this used 2004 Freestar. Within days the engine would fail while driving. Transmission shifting issues. Not starting. Etc.. Had transmission replaced before knowing of recall on that item. Still had the issues. Pulled out PCM and it was filled with water. Installed new one. I live in florida. Rainy season. Issues happened again within a week. New PCM removed and was filled with water. I myself found the service bulletin about the issue as well as several complaints by owners on the internet. My local dealership walker Ford swept the issue under the rug and wanted to charge $900 to find the leak. I showed them the bulletin that they were un aware of. They would not replace my PCM without charging me again. Went to another dealership and paid for new PCM and told them to perforce service bulletin. Seemed fine until last 6 months. Starting to stall a lot. …
Van started running poorly suddenly, then would not run at all. After shutting down and allowing cool down time, restarted van and it would not go into gear. Ran well in park or neutral, but shifting into any gear would "clunk" and the engine would immediately quit. After 5 days of troubleshooting, traced trouble to engine PCM after reading in on-line forums about it. Found PCM wet and pins on PCM and contacts on wire harness corroded and green due to water leaking past cowl-to-body seal. The PCM connector is not sealed, so if water does drip on it, it is dripping directly onto back side of the contacts and Ford did release a TSB about this issue but not a recall. …
My husband was driving on a 4 lane hwy in pensacola, fl when my 2004 Ford Freestar suddenly stopped pulling. No forward, no backwards, neutral, nothing and the rpms went extremely high. Zero warnings, and in heavy rush hour traffic. It is only due to my husbands race car driving experience and quick reaction time that he was immediately able to get the van on the side of the hwy. My husband and our two boys thankfully were safe but they were stranded in intense florida heat. I have had a lean fuel, various electrical, coil pack and PCM issues since I got the van June 2007. The Ford dealership, and the easterns dealership I purchased the van from, could not figure out the problems. While under warranty, easterns worked on it but none of the issues were ever able to be fixed. I choose the Freestar for its safety features so I knew I had a safe way to transport my children. …
Every single time gas is being pumped into the car the pump stops several times. It can take up to 20 minutes to completely fill the gas tank. Not only does it just stop, it frequently spits gas back out. The gas, which is a chemical, has given at least 2 people chemical burns on multiple occasions. Ford has been contacted and while this is a "known issue", they refuse to replace and/or repair unless I pay for it out of my pocket. This is a manufacturing defect, it happens often enough to be a known issue, it is dangerous in many different ways and I believe that this should most definitely be a recall due to the chemical burns that have already happened. Also the potential devastation that could happen if someone at a gas station throws a still burning cigarette butt down and it lands in the remains of the gas that has been spit back out and onto the ground. …
Many issues with the van & they continue. Purchased from 1 previous owner, jan '09 around 60K May 2010, 74K miles- replaced spark plugs & wires, fuel system cleaner: rough idle $432.23 dec 2010, 83K miles - replaced front axle & sway bar links: $822.89 April 2011, ? Miles, - replaced plugs & wires, coil pack: rough idle $700.85 jan 2012, 100K miles - replaced pvc EVAP hose, r&r fuel filter, fuel injector cleaner: rough idle $228.40 aug 15 2012, 106K miles - recall, torque converter replaced: costing me $162.14 to replace seals & transmission filter aug 16 2012, 106K miles - replaced EGR valve: rough idle & engine light on after recall fix $135.95 (dealership was kind enough to only charge for labor) aug 31, 2012, 107K miles - engine is still running rough, piercing noise while driving, sometimes it goes away when I am turning.
I started having problems fueling my 2004 Freestar after I began driving on gravel roads here in central missouri. The tank vent kept getting clogged up and when I tried to fill fuel tank, pressure would build in tank causing fuel to come spraying out of fill spout. I had gas sprayed on hands and clothing repeatedly. I finally had a mechanic reroute fuel vent line to air intake in motor compartment. Now I no longer have trouble. It cost me about $ 250 to have this done. I believe the problem is a flaw in design. My mechanics inlaws have the exact model as mine and have same problems. Please advise about reimbursement for repair. Thanks!
Fuel System complaints in other Freestar years
Frequently asked questions
How common are fuel system problems on the 2004 Ford Freestar?
NHTSA has 23 complaints about the fuel & propulsion system of the 2004 Ford Freestar, 2% of the model year's 1,227 complaints. The component named most often is delivery (1 mentions).
Is there a recall for 2004 Ford Freestar fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 87,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 3 injuries to fuel & propulsion system 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.