Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
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.
An incident from about a month ago: after traveling on the freeway and coming to a stop at a red light at the off ramp at 2 am, my car began to sputter and rev. I proceeded to the next red light where my car shut off. Every time I started it, it would shut off right away. I drive for a taxi service and luckily I did not have passengers in the car with me at the time. I called a family member to come look and help. He ended up pushing my car with his into a nearby parking lot. After some investigation, I concluded it was the PCM. It was taken out to dry completely and the windshield area where water May have leaked into it was sealed with silicone. It started working again fine and has been since then. Now it has rained again and the problem has reoccurred. Today, after driving on the freeway and entering a neighborhood, my trans-axle light started blinking. …
This is a big, big, deal related to dangerous safety issue. Reference bulletin:Ford TSB 6-14-10, issued July 24, 2006 (supersedes Ford TSB 5-23-7 issued November 28, 2005) my car suddenly lost control surging and unable to shift and no reverse gear. Have had off and on problems for the past year resulting in about $2000 of service to figure out why car acting up, surging, inability to shift, at times no forward or reverse gear. One time drove 25 MPH to get home 20 miles and police stopped me because suspicious driving. I told him I was have transmission problems. Transmission as it turns out is perfect. PCM is malfunctioning intermittently because of engineering problem of PCM shorting out.towed to Ford dealer and said needed $2-5000 transmission. Towed home and suddenly started working. …
Water dripped from the wiper blade cowl into the PCM, causing the vehicle to start, drive briefly, and then shut off while moving, causing loss of control of electrical components of the vehicle while driving on the highway. Steering became difficult. If this had happened at high speeds or with a lot of traffic around, it could have been extremely dangerous or deadly. The mechanic says this is a problem he sees with Ford windstar vehicles. The mechanic stated the PCM was literally under water when he received the vehicle, despite the cause being a fairly typical rain storm, and drying out the PCM did not help, as the damage had already been done. This is a safety issue that, after searching online and speaking with mechanics, appears to be common. Ford needs to fix this issue before a vehicle loses control at high speeds.
Purchased a 2005 Ford Freestar March 2009. Has suffered from repeated loss of motive power with the computer often recording "no codes" per the dealer. Has been to the dealer atmultiple times for various supposed repairs including new computer, alternator, etc., but the problem continues. The vehicle shuts off unexpectedly while driving causing a loss of power steering and brake control. This has occurred at least 8 times in the last 12 months and we left the vehicle at the dealer from 9/10/09 through 11/12/09 and again from 11/15/09(?) through 2/5/2010 due to our concerns about the vehicle's safety. On 2/10/2010 an accident occurred where the vehicle lost power, the road turned and the driver was unable to make the turn or brake adequately and hence ran off the road sustaining neck injuries.
While driving down the road, the van will suddenly die. All alarms, engine light, ABS, traction control. Will go off. Sudenly there is no power. Van will start right back up and drive again. This has been going on for over a year. I have had it at 7 different mechanics, including the Ford dealership where I purchased the vehicle. It has happened at all different speeds, 20-65, also happens if stalled at a stop light or drive-thru. Additionally, I can be driving at 25-35mph and the RPM's will shoot up to 7000 or fall all the way down like you are idleing. Vehicle makes noises like it is going to blow up and then will be fine.
While driving at 70 MPH the van stopped running. I was unable to restart it. I also lost all ability to steer. This happened during a very busy time on the highway. I was stranded in the middle of a lane with traffic around me continuing to go 70 miles per hour. After researching, my mechanic found that the problem is the PCM is getting wet due to a design flaw by Ford motor company. This was a very dangerous situation for me to be in. The van continues to have problems with moisture even though the PCM has been changed and all known areas have been sealed. This vehicle is dangerous.
For a few years now various electrical thing have been going on my Mini van. The screen that shows mileage, etc. Has a short and can only be seen when it's really dark out at night. Awhile later, as I was driving, my cruise control gave out and no longer works. Now the light for my clock and the screen that tells cardinal directions and the temp outside is dead. I am concerned that this electrical issue could be dangerous. I didn't know about this website to report it till now.
Drove the vehicle 1 mile to kids school on the way back it lost power , wouldn't accelerate .. The #40 fuse was blown and every time I replace it as soon as I turn the key on it blows again. Can't drive it and just seems like electrical problems keep occurring with it last time was water in the PCM causing other issues, May be the PCM again I don't know but these free stars are bad for this evidently. . Bad design and definitely bad for business..
Tl* the contact owns a 2005 Ford Freestar. While driving at various speeds during rainy weather conditions, all of the lights on the instrument panel illuminated and the engine stalled without warning. The vehicle did not restart. The vehicle was towed to the contact's residence where it was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 125,000.
Electrical complaints in other Freestar years
Frequently asked questions
How common are electrical problems on the 2005 Ford Freestar?
NHTSA has 85 complaints about the electrical system of the 2005 Ford Freestar, 10% of the model year's 886 complaints. The component named most often is instrument cluster/panel (1 mentions).
Is there a recall for 2005 Ford Freestar electrical problems?
No. NHTSA lists no electrical system recall for the 2005 Ford Freestar, though it has 3 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 2005 Ford Freestar electrical problems start?
Half of the complaints with a recorded mileage happened before about 98,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 1 injury to electrical 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.