Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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 traveling 30 MPH, the contact noticed that the front suspension and axle had suddenly separated from the vehicle, causing the vehicle to crash into a parked vehicle. No one was injured during the crash. The vehicle was not diagnosed or repaired for the failure. The current and the failure mileages were 87,308. Updated 05/10/12 the consumer stated while driving, the right tire on the passenger side of his vehicle simply collapsed. There was a loud bang as the front side dropped gouging the hub cap and the metal wheel into the asphalt leaving a narrow strip in between my wheel and the another vehicle that was double parked. His vehicle continued to gouge the asphalt and then stopped. The collapsed tire did rub the left lower side sport trim of the other vehicle which left black rubber marks on the double parked vehicle. …
Tl* the contact owns a 2004 Ford Freestar. The contact stated that the transmission did not function properly. The lever was heavy and became stuck before switching into gear. Sometimes, the vehicle hesitated and made an abnormal whining sound. Also, the axles made a crunching and grinding sound whenever the vehicle made a turn. The transaxle warning indicator illuminated. The vehicle was taken to an independent mechanic, but the mechanic did not have the equipment to repair the transmission. The contact was informed that the cbs axles needed to be repaired. The manufacturer and dealer were not made aware of the failures. The vehicle was not repaired. The failure mileage was 270,000. .. Consumer took the vehicle to the transmission shop and was told the sudden power could be torque converter but needs to checked. Common failed transmission error.
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.
Problem #1 the passenger side window will not work . It's controll module was replaced it worked one time and stopped working again. Problem #2 the drive axle broke in traffic luckily we were stopping and were only going about 5 MPH. Problem #3 today after a night of heavy rain when the van was unlocked the radio came on before the key was even in the ignition. Which brings us to problem #4 the biggest and no doubt most expensive. The van started and was running kind of sluggish but ran fine in reverse but if you shift to drive the van shuts off. You cannot start it in neutral either. I have had 2 independent mechanics look at it today both say it is the torque converter. I looked it up and there is a recall but of course it's the weekend and I can't call to see if it's covered.
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. The contact stated that while an independent mechanic was servicing the vehicle, it was discovered that there were cracks on the rear axle. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 155,000. Djr
I own a 2004 Ford Freestar in virginia. Last week I took it in for the annual state inspection to find that the control arm/ball joint assembly on the passenger side was pending failure. This is a potential life-threatening accident waiting to happen. My vehicle has only 36,000 miles. The Ford service consultant told me that it should have lasted about 80,000 miles on average. Although my vehicle is out of warranty I expected that since this part was most likely defective that Ford would have replaced it for free. Not only did they refuse to do so but offered to fix it of $660. The part can only be purchase as a unit, in other words, you cannot get just the ball joint, you have to buy the whole assembly which Ford sells for about $487.. I must get this done, not only for safety but in order to pass my state inspection. …
The problem is the same that is described in ea12003. The attaching bracket for the rear seat fell out while the seat was folded into the floor. It became lodged in the inner portion of the rear wheel assembly. If this would have happened at high speeds, somebody could have easily been killed, by the rear wheel becoming restricted or this heavy plate bouncing down the road at another vehicle. The bracket is a u bracket attached to a plate that is welded flush to comprise part of the wheel well. To temporarily keep from losing the bracket, I held the bracket in place while setting the seats upright again so that the seat itself is holding the bracket in. There is now water from the road getting up into the passenger compartment. I hope that Ford issues a recall or offers a bolt on replacement soon. I've been mostly happy with this vehicle otherwise. …
Experienced a very loud squealing noise that appeared to be coming from the front wheels - this usually occurred at speeds >60 MPH. When the steering wheel was turned slightly to the right, the noise would cease. When the wheels were straightened again, the noise would continue. Took the vehicle to the dealer with no issues found. I had suggested at that time that the problem appeared to be front wheel bearing related or something of that nature - no issues found with the vehicle at that time. The problem continued. Took the vehicle back 2 months later - reported that this was a known issue for the bearings to be replaced (and some other non-specific work with the hubs). This is listed in the recall section for this vehicle as a known issue since 2004!! …
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.
Suspension complaints in other Freestar years
Frequently asked questions
How common are suspension problems on the 2004 Ford Freestar?
NHTSA has 25 complaints about the suspension of the 2004 Ford Freestar, 2% of the model year's 1,227 complaints. The component named most often is front › wheel bearing (3 mentions).
Is there a recall for 2004 Ford Freestar suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to suspension 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.