Ford Freestar problems
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Ford Freestar model years
Common Ford Freestar problems
The Ford Freestar, a minivan produced between 2004 and 2007, has been known to have several common problems based on complaints from owners. Two of the most frequently reported issues are EGR Orifice in Intake Manifold May Plug With Sludge and Cause Misfire, and Torque Converter Failure.
- EGR Orifice in Intake Manifold May Plug With Sludge and Cause Misfire
The EGR (Exhaust Gas Recirculation) system in the Ford Freestar is designed to reduce harmful emissions by recirculating exhaust gases back into the engine's intake manifold. However, the orifice in the intake manifold, which is responsible for managing the flow of gases, can become clogged with sludge over time.
This issue can lead to several problems, including engine misfires, poor performance, and decreased fuel efficiency. In some cases, the engine may even stall or fail to start altogether. The sludge buildup is often caused by the use of low-quality fuel or a lack of regular maintenance, such as not changing the engine oil or fuel filter as recommended by the manufacturer.
To address this issue, the EGR orifice may need to be cleaned or replaced, and the engine may require a thorough inspection to ensure that there is no further damage. Preventive maintenance, such as using high-quality fuel and following the recommended maintenance schedule, can help prevent this issue from occurring in the first place.
- Torque Converter Failure
The torque converter is a critical component of the automatic transmission in the Ford Freestar. It is responsible for transmitting power from the engine to the transmission and allowing the vehicle to accelerate smoothly. However, the torque converter in the Freestar has been known to fail prematurely, causing widespread and dangerous transmission problems for owners.
Symptoms of torque converter failure may include difficulty shifting, slipping, shuddering, or jerking during acceleration, and a complete transmission failure. In some cases, the torque converter may need to be replaced entirely, which can be a costly and time-consuming repair.
The torque converter failure in the Ford Freestar was investigated and eventually recalled, but it is unclear whether the recall covered everyone who was affected. It is important for Freestar owners to be aware of this issue and to have their vehicles inspected regularly to ensure that the torque converter is functioning properly.
In summary, the Ford Freestar has been known to have several common problems, including EGR Orifice in Intake Manifold May Plug With Sludge and Cause Misfire, and Torque Converter Failure. These issues can lead to serious engine and transmission problems, and can be costly to repair. Freestar owners are encouraged to follow the recommended maintenance schedule and to be aware of these issues to ensure the safety and reliability of their vehicles.
What was wrong with the Ford Freestar?
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL. What should you do: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE.
What is the Ford Freestar controversy?
In a class action filed in 2009, the plaintiffs claimed that Ford Freestar and Mercury Monterey minivans in 2004, 2005, and 2006 were built with a manufacturing defect in the vehicles' torque converter. In the District of Minnesota, they claimed Ford breached its express and implied warranties.
Is a 2007 Ford Freestar a good car?
The 2007 Ford Freestar offers good looks and strong safety ratings but falls flat when it comes to acceleration, handling, interior design and overall quality. Unfortunate as it is to say, any of its competitors would be a better choice if you're shopping for a minivan.
What happened to the Ford Freestar?
The Freestar and Monterey minivan had nearly the same platform as the Windstar. The Freestar and Monterey minivan didn't sell too well because people were buying SUV's instead. This caused them both to stop being produced. Ford made the Ford Flex in 2008 to replace the Freestar and Monterey minivan.
Percentage distribution of complaints by Ford Freestar years
We have researched Ford problems and analysed all the complaints filed against Ford Freestar cars and compiled the top 4 most problematic Ford Freestar model years:
Below you can see the percentage distribution of known problems by Ford Freestar model years.
Distribution of the number of complaints by Ford Freestar years
We've also compiled a chart for you with the number of complaints about Volkswagen Jetta cars of certain model years:
Ford Freestar car problems categorized by type of issue
After analysing all complaints related to Ford Freestar , it was concluded that the most common issues with these cars are:
- Power train problems
- Electrical system problems
- Engine problems
- Structure problems
- Seats problems
The graph below shows statistics for all Ford Freestar vehicle components and the number of complaints received.
Distribution of the number of complaints where the accident occurred by Freestar model years
A total of 29 complaints were registered in which the accident occurred. In the graph you can see the distribution of the number of complaints by model year.
Distribution of the number of complaints with fire by Freestar model years
There were a total of 20 complaints that resulted in a fire. In the graph you can see the distribution of the number of complaints by model year.
Distribution of the number of complaints with injuries by Freestar model years
There were a total of 41 complaints that resulted in a injuries. In the graph you can see the distribution of the number of complaints by model year.
Distribution of the number of complaints with deaths by Freestar model years
There were a total of 1 complaints that resulted in a death. In the graph you can see the distribution of the number of complaints by model year.
The NHTSA has received 2525 complaints about various vehicle components related to the Ford Freestar . Below are the 25 most recent complaints reported for Ford Freestar vehicles.
Latest 25 complaints
Ford Freestar 2005
- Date Of Incident: 2024-10-10
- Date Complaint: 2024-10-17
- VIN: 2FMDA51615B
- Components: POWER TRAIN
- Summary: The contact owns a 2005 Ford Freestar. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. The contact stated that the vehicle stopped in the middle of the street, however the engine was still on. The contact stated that the gear shifter did not function as intended. The contact stated that the gear shifter did not shift. The contact was able to coast the vehicle to the shoulder of the road. The contact and her son pushed the vehicle to the nearest parking lot. The vehicle was not diagnosed or repaired by an independent mechanic. The manufacturer was not made aware of the failure. The failure mileage was unknown.
Ford Freestar 2007
- Date Of Incident: 2024-09-15
- Date Complaint: 2024-09-23
- Components: SEATS
- Summary: The contact owns a 2007 Ford Freestar. The contact received notification of NHTSA Campaign Number: 13V081000 (Seats); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. The VIN was unavailable.
Ford Freestar 2004
- Date Of Incident: 2024-08-25
- Date Complaint: 2024-08-27
- VIN: 2FMZA57604B
- Components: POWER TRAIN,ENGINE
- Summary: 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.
Ford Freestar 2005
- Date Of Incident: 2024-05-26
- Date Complaint: 2024-06-27
- VIN: 2FMZA57695B
- Components: POWER TRAIN
- Summary: I was driving and my transmission stopped working left me stranded
Ford Freestar 2005
- Date Of Incident: 2024-06-14
- Date Complaint: 2024-06-18
- VIN: 2FMDA51615B
- Components: POWER TRAIN
- Summary: The contact owns a 2005 Ford Freestar. The contact stated while driving 70 MPH and releasing the accelerator pedal, the contact noticed an abnormal clucking sound. The contact stated that upon depressing the accelerator pedal, the vehicle failed to respond. The contact pulled to the side of the road. The contact stated he was able to continue driving; however, the failure persisted. The contact stated that upon depressing the accelerator pedal, the vehicle only responded when the RPMs were high, and the vehicle failed to exceed 30 MPH. The vehicle was taken to an independent mechanic, where it was diagnosed that the torque converter output shaft had failed. The mechanic determined that the torque converter and the output shaft needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The contact related the failure to NHTSA Campaign Number: 12V006000 (Power Train). The manufacturer was notified of the failure and informed the contact that they could not assist because the vehicle was previously repaired under the recall. The failure mileage was approximately 350,000.
Ford Freestar 2004
- Date Of Incident: 2024-03-18
- Date Complaint: 2024-03-18
- VIN: 2FMDA58294B
- Components: POWER TRAIN
- Summary: 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
Ford Freestar 2006
- Date Of Incident: 2024-02-08
- Date Complaint: 2024-02-09
- VIN: 2FMZA51656B
- Components: POWER TRAIN,UNKNOWN OR OTHER
- Summary: My Ford Freestar without warning or anything just wouldn’t go after stopping at a stop sign. It was like it was stuck in neutral. But it was in drive. In 2003 and 2004 there was a recall on the transmission. My van is a 2005 but the transmission was manufactured in 2004. Which is one of the years that was recalled so why is my 2005 Ford Freestar van not one of the ones under that recall. Is it cause it’s a 2005 cause the transmission was manufactured in 2004. I almost got hit by semi truck when this happen. Please recall this van. Please help!!! [XXX] Bless you all. Thanks, [XXX] Family INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Ford Freestar 2006
- Date Of Incident: 2023-08-16
- Date Complaint: 2023-10-12
- VIN: 2FMDA51626B
- Components: POWER TRAIN
- Summary: The contact owns a 2006 Ford Freestar. The contact stated that while driving at an undisclosed speed, the vehicle lost all motive power and would not shift to any gear other than park. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related it to a possible recall but was unable to provide details. The manufacturer was notified of the failure but referred the contact to the NHTSA hotline for assistance. The failure mileage was 85,000.
Ford Freestar 2006
- Date Of Incident: 2023-01-15
- Date Complaint: 2023-10-10
- VIN: 2FMZA52286B
- Components: POWER TRAIN
- Summary: The contact owns a 2006 Ford Freestar. The contact stated that while driving at an undisclosed speed, the vehicle lost significant motive power before briefly hesitating and jerking. After restarting the vehicle, it returned to normal functionality, but the failure had since become a regular occurrence. The check engine warning light was illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. The manufacturer was notified of the failure but referred the contact to the NHTSA hotline for assistance. The failure mileage was 137,000.
Ford Freestar 2004
- Date Of Incident: 2023-05-01
- Date Complaint: 2023-10-03
- Components: POWER TRAIN
- Summary: 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.
Ford Freestar 2005
- Date Of Incident: 2022-11-11
- Date Complaint: 2023-07-14
- VIN: 2FMZA57605B
- Components: POWER TRAIN
- Summary: The contact owns a 2005 Ford Freestar. The contact stated that upon selling the vehicle, she allowed another individual to test drive the vehicle; however, as the contact was driving on an incline, the vehicle stalled. The vehicle was taken to the dealer where it was diagnosed that the flex shaft had failed. The contact then stated that upon research, she became aware of NHTSA Campaign Number: 12V00600 (Power Train). The vehicle was not repaired. The contact stated that she received notification of the NHTSA Campaign Number: 13V081000 (Seats). The vehicle was taken to the dealer where the contact was informed that due to the condition of the vehicle the recall repair could not be performed. The contact was concerned that when the vehicle was taken to the dealer, the VIN was entered and displayed a different color. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 180,000.
Ford Freestar 2005
- Date Of Incident: 2023-03-10
- Date Complaint: 2023-03-10
- VIN: 2FMZA516X5B
- Components: ELECTRICAL SYSTEM,STRUCTURE,SEATS
- Summary: 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.
Ford Freestar 2005
- Date Of Incident: 2023-02-15
- Date Complaint: 2023-02-17
- VIN: 2FMZA52285B
- Components: POWER TRAIN
- Summary: Driving down highway at 60 mph lost all power basically coasted to side of road. Looks like torque converter and pump shaft splines stripped out. Shows there was a recall but none listed for this vin number. This is a huge safety concern and Ford should have to repair.
Ford Freestar 2004
- Date Of Incident: 2022-12-16
- Date Complaint: 2023-02-16
- VIN: 2FMZA51654B
- Components: ENGINE
- Summary: Conducía mi vehículo y la trasmisión quedó en neutro en una entrada y no pude estacionarme Y no volvió arrancar Solo coje la reversa I was driving my vehicle and the transmission was neutral in a driveway and I couldn't park And did not start again Just take the reverse
Ford Freestar 2005
- Date Of Incident: 2023-02-02
- Date Complaint: 2023-02-07
- VIN: 2FMDA52245B
- Components: POWER TRAIN
- Summary: I was having issues with my car not able to really move so I had a mechanic to come to me to inspect it and he stated it was my torque converter someone on it in it near it.. That my issue.. So I was calling about the recall on it and it stated that it was already fixed in 2012 on recall. And I'm a new owner purchased in 2018.. I'm a Ford girl.. So from the Taurus 500 and freestar never had of it needed a van have grandkids and now out my four year with it no problem with til now and by it has been replaced before I'm not able to get help with fixing it .. That my only car now I'm now disabled on fixed income and can't afford to buy a new transmission.. I'm asking if u could assist me with the same issue happening twice with vehicle with two different owner.. Thanks for your assistance and help
Latest 5 recalls Ford Freestar
The National Highway Traffic Safety Administration (NHTSA) has issued 14 recalls for different components of the Ford Freestar.You can explore the year of the Volkswagen Jetta you are interested in by selecting it from the list.
- Model: Ford Freestar 2007
- Report Received Date: 2013-03-07
- Manufacturer: Ford Motor Company
- Components: SEATS
- Summary: Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
- Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
- Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
- Model: Ford Freestar 2005
- Report Received Date: 2013-03-07
- Manufacturer: Ford Motor Company
- Components: SEATS
- Summary: Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
- Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
- Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
- Model: Ford Freestar 2006
- Report Received Date: 2013-03-07
- Manufacturer: Ford Motor Company
- Components: SEATS
- Summary: Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
- Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
- Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
- Model: Ford Freestar 2004
- Report Received Date: 2013-03-07
- Manufacturer: Ford Motor Company
- Components: SEATS
- Summary: Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
- Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
- Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
- Model: Ford Freestar 2005
- Report Received Date: 2012-01-09
- Manufacturer: FORD MOTOR COMPANY
- Components: POWER TRAIN:AUTOMATIC TRANSMISSION
- Summary: FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
- Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
- 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.
Latest negative Ford Freestar car reviews
Latest positive Ford Freestar car reviews
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Vehicle year: 2005
Since 2001, I've been driving a 1998 Ford Windstar with a 3.8-liter engine. Unfortunately, the head gasket blew and the coolant level kept going down, so I decided it was time for a change. In January 2009, I traded it in for a 2005 Ford Freestar, which was available at the dealer. I'm happy to report that the 2005 version is a lot better and has big improvements over the 1998 version. It's a stable ride, although it is 1200 lbs heavier than the 1998 model. I mainly use the vehicle for work and carrying loads, and I occasionally tow. The only downside is that I'm getting around 19-20 mpg, even though it's supposed to get 24 mpg. Overall, I'm pleased with my purchase and I'm looking forward to many more years of driving it.
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Vehicle year: 2005
My family really enjoys this van, and our guests love how comfortable the ride is compared to my previous BMW sedan. There's plenty of room for everyone when we have relatives riding along, and so far it has been very reliable. When my parents came to visit, they were impressed with the quality of this Ford. Even my father, who had sworn off Fords after his earlier fiasco with his Mustang decades ago, was pleasantly surprised.
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Vehicle year: 2005
I love driving this vehicle! It's so comfortable and easy to park. I get about 22 mpg on the freeway and slightly less in town, but it's perfect for my work-related driving. Plus, there's plenty of cargo space. And I've never had any mechanical problems, thanks to following the manufacturer's service instructions carefully.
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Vehicle year: 2007
Your vehicle has performed as well as the 2000 Windstar it replaced, but with more power for trailer-pulling and better fuel economy. The dealer was able to correct the rear door rattles and front door misalignment. You'll find that it's very stable on the highway and has excellent visibility. Additionally, it's easy to lower the rear seat to carry longer cargo.
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Vehicle year: 2006
The 2006 Ford Freestar minivan is a great vehicle, but I understand your concern about the bench 2nd row seat. It seems to be more comfortable for kids than adults. Have you considered any alternative seating options?
Are you having problems with your Ford Freestar?
Lukas Casper 2025-10-21
Vehicle year: 2005
The van overall is nice and very roomy. However, there seems to be an issue with the front ends of these vehicles. It's almost like they were just thrown together...
Rod Bashirian 2025-10-15
Vehicle year: 2006
Hello! Thank you for sharing your experience with us. We're sorry to hear that you've had some issues with your vehicle. We appreciate your feedback and would like to help you resolve these issues as soon as possible. Please let us know how we can assist you further.
Peter Beahan 2025-10-12
Vehicle year: 2004
Our Freestar has been a major disappointment since we purchased it 5 months ago. Unfortunately, we have had to take it to the shop 4 times within the first 3000 miles of owning it. Despite having only 54000 miles on it, we have had to replace the coil pak, 2 crank shaft sensors, and 2 high speed output sensors. Additionally, the steering wheel shakes constantly and the transaxle light keeps coming on. We were unaware that it had a new transmission when we bought it, and now, with only 59000 miles on it, we have had to tow it to the Ford dealership for a new transmission. We strongly advise against purchasing this vehicle as it has proven to be a major financial burden and a significant disappointment for the Ford company. It is our belief that every Freestar should be recalled.
Raoul Rosenbaum 2025-10-08
Vehicle year: 2004
Although I have experienced some issues with this vehicle, I have taken the necessary steps to address them. I have replaced the radio, computer, power window motors, ABS sensors, half shaft, egr sensor, and have had to replace the rotors, calipers, and brakes multiple times. Despite these challenges, I have driven this vehicle for 90000 miles. I am now considering trading it in for a Honda Odessey.
Reynold Erdman 2025-10-05
Vehicle year: 2004
Hi there! I wanted to share my experience with my 2004 Freestar Limited. Unfortunately, my previous car, a '94 Aerostar, was in an accident and I had to find a new one. While I've had a few issues with the CV joint, the dealership has been very helpful in replacing it twice already. They even went out of their way to find a replacement part from a 2005 model when needed. Currently, my car is at the dealership for a vibration issue with the right passenger tire, but I'm confident they'll take care of it. Overall, I've owned this car for 57 days and while it's had a few bumps in the road, I'm still happy with my purchase. Thanks for listening!