VehicleVerdict

2004 Ford Freestar problems

Verdict · NHTSA data

One of the years to avoid

With 1,600 complaints filed to NHTSA — about 2.1 times the median Freestar year — the 2004 model ranks #1 of 4 Freestar years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include one death and 29 injuries, per the complaint records themselves.

The trouble concentrates in one system: transmission issues account for 55% of all reports (873 of 1,600), far ahead of electrical system at 132.

1,600

NHTSA complaints

5

Recalls

8

Investigations

25

Crash-involved

17

Fires reported

29

Injuries

1

Deaths

—

NCAP overall

How does 2004 compare to other Freestar years?

Freestar NHTSA complaints by model year, 2004 highlighted1,600 complaints2004: 1,600 complaints2005: 1,093 complaints2006: 453 complaints2007: 77 complaints
Freestar NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Freestar years to avoid →

What are the most common 2004 Ford Freestar problems?

ComponentComplaintsShare
Transmission87355%
Electrical System1328%
Engine1187%
Body & Structure956%
Seats875%
Brakes725%
Speed Control332%
Other312%
Tires & Wheels312%
Suspension282%
Steering272%
Fuel System231%
Visibility & Wipers161%
Latches & Locks141%
Airbags91%
Seat Belts60%
Lighting30%
Driver Assistance10%
Climate Control (A/C & Heat)10%

Does the 2004 Ford Freestar have recalls?

5 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

13V081000SeatsMarch 7, 2013 · 196,667 units

Defect

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.

12V006000TransmissionJanuary 9, 2012 · 206,452 units

Defect

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.

06E056000Fuel SystemJune 13, 2006 · 58,640 units

Defect

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

Consequence

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy

UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

04V446000Tires & WheelsSeptember 13, 2004 · 34,013 units

Defect

CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB.

Consequence

IF THE CRACKS WERE TO PROGRESS, THIS COULD EVENTUALLY RESULT IN WHEEL SEPARATION. WHEEL SEPARATION MAY LEAD TO LOSS OF VEHICLE CONTROL, AND POTENTIALLY RESULT IN A VEHICLE CRASH.

Remedy

DEALERS WILL REPLACE THE FRONT HUB, ROTORS, AND WHEEL BEARINGS. THE RECALL BEGAN SEPTEMBER 20, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

03V457000SteeringNovember 6, 2003 · 23,996 units

Defect

ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.

Consequence

IF THIS LINE BECOMES DISCONNECTED, IT MAY CREATE THE POTENTIAL FOR FLUID TO COME INTO CONTACT WITH THE EXHAUST SYSTEM, WHICH COULD RESULT IN SMOKE OR FIRE.

Remedy

DEALERS WILL INSPECT THE POWER STEERING LOW-PRESSURE LINE TO ENSURE THAT IT IS SEATED PROPERLY AT THE RACK AND PINION STEERING GEAR. OWNER NOTIFICATION BEGAN NOVEMBER 10, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT WHILE THE VEHICLE WAS UNOCCUPIED AND IN PARK, IT ERRONEOUSLY ROLLED AWAY AND CRASHED INTO A HOUSE. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED…”

Complaint filed with NHTSA · Transmission · August 19, 2013 · crash

“UPON LEAVING THE INTERSTATE AND COMING INTO TOWN (APPROXIMATELY 1 MILE ) MY VEHICLE MADE A SLIGHT NOISE, I LOOKED AT MY GAUGES WITH NO INDICATORS ON I PROCEEDED INTO MY DRIVEWAY WHERE MY VAN BEGAN TO ERUPT INTO FLAMES WITHIN MOMENTS THE ENTIRE FRONT END WAS ENGULFED WITH 12 FT. FLAMES I CALLED THE…”

Complaint filed with NHTSA · Electrical System · July 10, 2006 · fire

“DRIVING NORTH ON MINNESOTA HIGHWAY 169 AT 65MPH AND NOTICE SMOKE COMING FROM THE ENGINE COMPARTMENT. I IMMEDIATELY PULLED OVER ONTO THE SHOULDER AND WITHIN THREE MINUTES THERE WERE FLAMES COMING FROM THE ENGINE COMPARTMENT AS WELL AS SMOKE. THERE WAS NOTHING WRONG WITH MY VEHICLE AND IT WAS RUNNING…”

Complaint filed with NHTSA · Engine · March 18, 2012 · fire

“THIS VEHICLE I RECEIVED NUMEROUS RECALLS AND HAD MANY PROBLEMS WITH THIS VEHICLE. MAJOR ELECTRICAL PROBLEMS. WHEN IT WOULD RAIN AND GET CAR WASH THE ELECTRICAL SYSTEM WOULD MALFUNCTION AND CAUSE ENGINE NOT TO RUN PROPERLY AND CHECK ENGINE LIGHT WOULD COME ON. IN APRIL OF 2016 ENGINE WAS…”

Complaint filed with NHTSA · Body & Structure · April 20, 2016 · crash

“2004 FORD FREESTAR [XXX]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…”

Complaint filed with NHTSA · Seats · February 24, 2017 · crash

2004 Ford Freestar — common questions

Is the 2004 Ford Freestar reliable?

NHTSA data argues against it: 1,600 complaints put the 2004 model at #1 of 4 Freestar years. It is one of the Freestar years to avoid.

What are the most common 2004 Freestar problems?

According to NHTSA complaint data, the leading problem areas are transmission (873 complaints), electrical system (132 complaints), engine (118 complaints).

Does the 2004 Ford Freestar have recalls?

Yes — NHTSA lists 5 recall campaigns affecting the 2004 Ford Freestar. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Ford Freestar under NHTSA investigation?

NHTSA opened 8 investigations into this model year; all are now closed.

Which Ford Freestar years should you avoid?

Based on complaint rates and open investigations, the Freestar years to avoid are 2004. The cleanest record among Freestar years belongs to 2007.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.