Problems · NHTSA complaints

2004 Ford Freestar problems

Owners filed 1,227 complaints about the 2004 Ford Freestar with NHTSA between Mar 2004 and Jul 2025. The most-cited component is power train (851).

Complaints
1,227
Filed with NHTSA
Crashes
16
Reported by owners
Fires
14
Reported by owners
Injuries
21
People reported injured
Deaths
1
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Power train851
  2. Electrical system118
  3. Structure94
  4. Seats86
  5. Engine69
  6. Engine and engine cooling49
  7. Service brakes, hydraulic44
  8. Vehicle speed control33
  9. Steering27
  10. Wheels25
  11. Suspension25
  12. Visibility15
  13. Fuel system, gasoline15
  14. Equipment15

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Nov 10, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200416
200528
200615
200735
2008103
2009171
2010193
2011170
2012177
2013107
201450
201538
201632
201731
201818
201919
20207
20217
20223
20233
20242
20252

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Power train

851 reports6 crashes7 fires1 related recall
“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.”
Owner complaint to NHTSAFiled Jul 11, 2025Power trainODI 11672730

Electrical system

118 reports2 crashes1 fire
“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.”
Owner complaint to NHTSAFiled Jan 18, 2023Power train, Electrical system, Back over preventionODI 11502520

Structure

94 reports1 crash1 fire
“THE PART THAT HAS THE CLIP FOR BACK SEAT FELL OUT AND NOW THERE IS A 5 BY 5 INCH HOLE GOING INTO THE WHEEL WELL AND THE SEAT HAS NOTHING TO CLIP ONTO AND BE SECURE, THIS WAS RECALLED IN THIS MODEL”
Owner complaint to NHTSAFiled Dec 3, 2020Structure, SeatsODI 11377831

Seats

86 reports1 crash1 related recall
“The contact owns a 2004 Ford Freestar. The contact stated that the third-row seat floorboard was corroded with several holes. The TPMS warning light was illuminated. The contact received notification of NHTSA campaign number: 13V081000 (Seats) however, the part to do the recall was unavailable. The vehicle was taken to the local dealer who declined to repair the vehicle due to part availability issues. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure. The failure mileage was approximately 150,000. Parts distribution disconnect. (RECALL REMEDY INCIDENT) TS”
Owner complaint to NHTSAFiled Jun 29, 2021SeatsODI 11422810

Engine

69 reports3 crashes2 fires
“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.”
Owner complaint to NHTSAFiled Aug 27, 2024Power train, EngineODI 11611067

Engine and engine cooling

49 reports4 fires
“TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE BACK SEAT NEAR THE REAR WHEEL WELL BECAME DETACHED AND THE CONTACT SMELLED AN EXHAUST ODOR. THE CONTACT STATED THAT THE VEHICLE EXHIBITED THE SAME SYMPTOMS AS LISTED IN NHTSA CAMPAIGN NUMBER: 13V081000 (SEATS). THE VEHICLE WAS NOT TAKEN TO A DEALER TO BE DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 168,867.”
Owner complaint to NHTSAFiled Oct 25, 2018Engine and engine cooling, SeatsODI 11142642
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.