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 2005 Ford Freestar owners, lightly cleaned up (personal details are redacted by NHTSA).
The rear wheel well has rusted on both sides and completely rusted out a large hole (approx. 1 ft diameter area visibly effected) in the the body of the van. The rusted out section is where the back seat is anchored to the frame, so the rust has cause the seat to no longer be securely anchored to the car. The hole has also caused electrical wires to get wet when water gets into the van and intermittently and unpredictably causing failure of electrical features, including headlights and blinkers, while driving.
I wrote on this yesterday but did some more research on this vehicle. There have been numerous recalls on these type of vehicles. Recall #12V006000 on the torque converter output shaft. Recall began August 9 2012. This is a serious matter I just recently purchased this vehicle to take my 8 grandchildren around. Now I won't even put them in it. I also found out there was a recall on the back seat. Recall # 13V081000. This is also a problem when your hauling around children. The undercarriage of the vehicle is really rusty. I wish I would of never bought this vehicle. It sure is going to be a money pit for sure. It only has 141000 miles on it. Very sad that Ford could make such a unsafe vehicle. I bought the vehicle and it seemed fine. 5 days into ownership the torque converter light came on while I was driving it. …
Tl* the contact owns a 2005 Ford Freestar. The contact stated that when stopped at a grocery store, the rear passenger side door was locked and failed to unlock both from the interior and from exterior. The failure occurred without warning. The dealer sherwood of salisbury located at 1902 n salisbury blvd, salisbury, md 21801; [phone] was contacted and confirmed that they were unaware of the failure and needed to be inspected. The dealer also stated that the contact would have to pay for the repair. The vehicle was not diagnosed or repaired. The manufacturer was contacted at [phone]. The manufacturer was made aware of the failure and stated that there were two recalls but no recall for the failure. A case number was provided: cas-12779247-c5y2k4. The failure mileage was 140,000.
Tl* the contact owns a 2005 Ford Freestar. While attempting to move the third row seat back into an upright position, the seat failed to latch. The contact found that the metal around the seat latch was rusted. The contact then noted that the rear wheel wells also showed severe rust. The vehicle was not diagnosed or repaired. The contact spoke to a dealer who stated that they were aware of the issue. The manufacturer was made aware of the failure and stated that the vehicle was not included in a recall and advised the contact to take the vehicle to a dealer. The approximate failure mileage was 162,015.
Tl* the contact owns a 2005 Ford Freestar. While driving 35 MPH, the contact heard an abnormal noise from the rear passenger side of the vehicle. Upon parking the vehicle, the contact noticed that the rear wheel well was rubbing against the rear wheel. The contact removed the metal part of the seat bracket from the wheel well and continued driving. The vehicle was not diagnosed or repaired. Recently, the rear driver side experienced the same issue. The manufacturer stated that the VIN was not included in NHTSA campaign number: 13V081000 (seats). The failure mileage was 180,000.
Tl* the contact owns a 2005 Ford Freestar. The contact stated that both rear sliding doors did not work and failed to open manually. The failure made it a safety hazard for rear passengers in the event of an emergency. The vehicle was not taken to the dealer for diagnostic testing. The manufacturer was not made aware of the failure. The failure mileage was approximately 199,000.
While you are driving the vehicle. The vehicle has something wrong with the transmission. I looked up Ford recalls and it states that this type of vehicle has been recalled for transmission problems. Torque something thing. The van has only 141000 miles and is rusted severely underneath it. Very sad.
I have had recurring problems with my automatic rear doors. The door on the driver side does not always close properly and when I back up the door ajar light comes on. The passenger rear door does not open with the overhead button all the time, it does not seem to unlock. I have had it in the shop several times (at least 6 or more) and most of the time they say they can't duplicate the problem even though they have seen the door not close properly before. They ordered parts and said it was "fixed" but I'm still having the problem and again they say they can not duplicate the problem. I have explained to them that my toddler sits in the seat behind me and it is dangerous when I'm backing out and the door opens!!!! The dealership said they have contacted Ford and they have not had any reports of this kind of problem, however I have found several complaints over the internet. …
I have had problems with my Ford free star 2005 van it has 50,600 miles on it. It all started when the speedometer and odometer stopped working at highway speeds. Then a few seconds latter the van just died while driving with my two year old twins in the car. I was able to start it up again and it started to sputter and stall again. I am a mechanic and I was going to attempt to repair the vehicle myself until I went on line and found out that other people have been complaining about the PCM getting wet and I found out mine was wet and corroded. The PCM was getting wet by water getting through the crowl gasket. I also found out that there was a TSB out on this directing dealers how to repair this problem at cost to the customer. The PCM was replaced now the vehicle shifts funny and goes in and out of gear and I was told I have transmission damage now. …
I had received a letter of recall of my back row seat latch do to corrosion. I had taken my van in to be repaired they informed me that they would have to order the parts which took 2 weeks upon returning they informed me they need another part they forgot to order so I waited for my call back again.. Within 2 months time I returned to have it worked on that is when they had told me it had begun to corrode n that they couldn't install the parts I asked them about the situation further & if it was safe to drive they had said yes & handed me my keys so upon leaving the dealership I had stopped for food on my way home I smelt burnt rubber then a thudding noise I had pulled over to check it out luckily I was to close to a family members house a piece had fallen off n was rubbing on my tire my tires had almost caught fire when luckily I had gotten the baby out before anything had happened …
Related recalls
Structure › Body › Hatchback/liftgate
On certain vans equipped with the power liftgate option, the power liftgate motor automatically disengages after the liftgate is powered open.
Remedy: Dealers will reprogram the power liftgate module to reduce the likelihood that the liftgate could fall free of charge. The recall began on March 15, 2006. Owners May contact Ford at 1-800-392-3673.
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 2005 Ford Freestar?
NHTSA has 33 complaints about the body & structure of the 2005 Ford Freestar, 4% of the model year's 886 complaints. The component named most often is body (13 mentions).
Is there a recall for 2005 Ford Freestar body problems?
Yes — NHTSA recall 06V-069 (hatchback/liftgate, Mar 9, 2006). Recall repairs are free at authorized dealers.
At what mileage do 2005 Ford Freestar body problems start?
Half of the complaints with a recorded mileage happened before about 82,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 7 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.