Which parts fail
Components named in complaints (automatic and manual transmissions, CVT, axles, driveshaft, 4WD/AWD).
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).
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.
The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An independent mechanic diagnosed that the torque converter and the transmission needed to be replaced. The contact related the failure to an unknown NHTSA Campaign Number; however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 104,000.
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.
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.
My son was driving down Rt 81 when the transmission stopped working Your vehicle was running fine but would not go had to drift off the highway she avoid getting hit I had to tow the van home we're it's still parked
Tl* the contact owns a 2004 Ford Freestar. The contact stated that the vehicle was taken to the dealer to be repaired under NHTSA campaign number: 12V006000 (power train) however, the dealer refused to remedy the vehicle. The contact was then informed that the transmission needed to be replaced. The contact declined. The contact stated that after leaving the dealer, and driving at 25 MPH, smoke filled the cabin of the vehicle. The vehicle was taken back to the dealer. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 120,000.
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. …
I bought this car in 2014. It stranded me on the side of the road it wouldn't go in reverse or drive. Finally after 4 hrs I got it to where I could drive it home. Took it to a shop and they said nothing was wrong they had to see it act up. Even though the check engine soon light was on and the light for the transaxle was on the shop said they put it on a diagnostic machine and it showed nothing. So I took it home and it when I drive it it jerks and the RPM's go to about 4000 RPM's before it shifts. I have had it 4 times at a shop and the same thing happened they couldn't find anything wrong. Now it has really gone bad. It no longer shifts you cant get it past 35 miles per hours because the engine would probably blow. I can't take it on the freeway but every shop I took it to said nothing is wrong. …
2004 Ford Freestar [redacted]Ford is charging me for the repair for the torque converter subframe 3-4 $600~$800 bushing kits ($200 each) they want to charge me. I informed them that only do the factory recall repairs the pulled my van out and told me the cant do the repairs, because they are scared of the ball joints and tie rods might break, then complained about the subframe my have to be cut to install new subframe bolts bushings etc. Just to they can continue to take the apart to replace the torque converter. The agreed to charge me 300 labor and told me to pick up the parts needed so I purchased 2 tie-rods. 2 transaxles l-r, 2 lower control arms which included ball joints. They took the subframe apart then told me I need to pay and additional $500 for a used subframe from the salvage yard. …
Related recalls
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.
NHTSA investigations
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…
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…
Transmission complaints in other Freestar years
Frequently asked questions
How common are transmission problems on the 2004 Ford Freestar?
NHTSA has 851 complaints about the transmission & drivetrain of the 2004 Ford Freestar, 69% of the model year's 1,227 complaints. The component named most often is automatic transmission (495 mentions).
Is there a recall for 2004 Ford Freestar transmission problems?
Yes — NHTSA recall 12V-006 (torque converter, Jan 9, 2012). Recall repairs are free at authorized dealers.
At what mileage do 2004 Ford Freestar transmission problems start?
Half of the complaints with a recorded mileage happened before about 85,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 6 crashes, 7 fires and 7 injuries to transmission & drivetrain 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.