2004 Ford Freestar fuel system problems

Filed Dec 20, 2019 · Fuel system, Transmission · PA

I have spent so much money in this van that I would like to report these issues to you first it was the fuel filter and now it's the transmission I keep the maintenance up and things still go wrong

Filed Feb 24, 2016 · Fuel system · 81,000 miles · TN

Tl* the contact owns a 2004 ford freestar. The contact stated that while parked, there was a strong odor of fuel outside of the vehicle. The entire fuel tank exhibited rust corrosion as a result fuel leaked from the outer part of the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 81,000.

Filed Jan 19, 2016 · Engine, Fuel system · 87,000 miles · NY

Tl* the contact owns a 2004 ford freestar. While driving approximately 70 MPH and suddenly on an elevation, the vehicle shook, decelerated, and lost power without warning. The contact pulled into an independent mechanic's shop where the technician changed the fuel filter. The failure recurred a few days later. The check engine light illuminated. The vehicle was taken to another independent mechanic who did not diagnose the failure. The manufacturer was made aware of the failure and stated that there was no recall. The VIN was unknown. The vehicle was not repaired. The failure mileage was 87,000.

Filed Apr 8, 2015 · Fuel system, Suspension · 185,600 miles · OK

As I proceeded to make a left hand turn,@ a permittible speed 25 m.p.h. I could hear noise emanating from the rt. Frt. Side of the veh. Fuel sys. Further ck'ing needed.

Filed Feb 12, 2014 · Acceleration, Fuel system · 117,000 miles · FL

Just purchased this used 2004 freestar. Within days the engine would fail while driving. Transmission shifting issues. Not starting. Etc.. Had transmission replaced before knowing of recall on that item. Still had the issues. Pulled out PCM and it was filled with water. Installed new one. I live in florida. Rainy season. Issues happened again within a week. New PCM removed and was filled with water. I myself found the service bulletin about the issue as well as several complaints by owners on the internet. My local dealership walker ford swept the issue under the rug and wanted to charge $900 to find the leak. I showed them the bulletin that they were un aware of. They would not replace my PCM without charging me again. Went to another dealership and paid for new PCM and told them to perforce service bulletin. Seemed fine until last 6 months. Starting to stall a lot. High hum when accelerating and turning. More research online and I found 2 more recalls on vehicle. The PCM issue should be a recall. Find out how to permanently fix the issue and perform it for free with a new PCM.

Filed Dec 19, 2013 · Engine, Fuel system · 15,000 miles · CA · crash · 1 injury

Purchased used vehicle from marshall used cars in sacramento, ca, where reside currently. Purchased 05/2011, paid full no loan at time of purchase. Purchased add. Ext. Warranty which was 6months. From the dos til present date; I have paid, and was mislead in all the insurance covering major defects, owner(me) had came out of pocket paying for service to fix warranty parts. Now this is the current and serious issue. I am disabled, I have a disable child. My vehicle was reported under VIN to ford corporate to notate for service to be check and worked on at local ford dealer. Complained about multiple (4) issues. Dealership mislead me, and did not perform work. Only work they did was replace 1 recall 10/12. After recall service I (owner) recall manufac. Made claim, again and then went to dealer. I was turned away...and told to do normal maintenance before putting a service claim in. This is a problem. I am not ignorant to the anatomy of a vehicle. I am very literate on understanding vehicle operations as well as maintaining maintenance. I can say this because I believe I should be aware of every issue so I wont have a disabled vehicle. Vehicle mileage applied from the date recall replaced 5800 within the time til I made another claim in oct 2013. Took vehicle in, told to check everything. Did. Brought vehicle back and vehicle was in service dept for week which rolled over to nov 1, 2013. Vehicle was dx and found to be the same thing I made a claim about. Vehicle has a defected recall part. Part was not replaced. And owner is now left with a defect recall part, plus more damage on other parts related to torque converter, fuel line, 3rd bench, front r-wheel hub. I have multiple health appts to maintain for me and my child's disability. My children need to get to school, and I missed legal appt dates from court.

Filed Oct 11, 2013 · Acceleration, Fuel system · 205,000 miles · NY

I currently own a 2004 ford freestar minivan. I have been experiencing start problems for a couple of weeks now. I drove the car about 10 miles to get gas. I turned the engine off to fuel up. I attempted to start the vehicle and it would not start. I called my husband to try to jump start the vehicle and it worked. Drove the car 1/4 mile down the road to autozone to have the battery tested. The battery needed to be replaced. The vehicle seemed to be repaired after the battery was replaced. About 5 days after the battery was replaced the vehicle would not start after several attempts. I called aaa to have it towed to the ford dealership for repairs. The aaa mechanic tried to start it before just towing it. He moved the shifter to neutral and back and started to vehicle right up. Maybe I did not have the shifter in the proper position? Since then, the vehicle has not started up quite a few times....at random times, over the last few days. I was stranded at the doctors office with a no start. Called aaa again for a tow again. However, right before aaa got to me....the vehicle started right up. I cancelled the aaa call and drove straight to the dealership for repair. The ford dealership can not find any problem as to why the vehicle will not start. It starts every time for them. The alternator and the starter are fine. The battery has been replaced and there are no transmission error codes being emitted.I have a hunch that this is an electrical problem. It isn't anything else. The ford dealership explained that they took a look at the PCM but could not see any water corrosion. So they did not replace it. So now, I am faced with picking up the vehicle and not knowing when I'll be stranded again because the vehicle will not start.

Filed Sep 5, 2013 · Engine, Fuel system · 124,000 miles · MI

Intermittently, when I am idling in drive (like at a light) with my foot on the brake, the van will begin to surge and lurch forward, sometimes violently. Only pressing hard on the brake will keep it from moving forward and causing a crash. Sometimes happens in reverse also. The tachometer will surge up to higher rpms and back down as it lurches. Sometimes, if it is violent enough, the battery light will flash off and on as if the vehicle is about to stall. Seems very dangerous as it could cause an accident with a nearby vehicle.

Filed Aug 24, 2013 · Fuel system · 125,000 miles · IL

Starting about a year ago this vehicle shoots gas out while trying to fill up. Gas will shoot out all over whomever is putting it in. It also shuts the pump off without being full.this happens every time.

Filed Aug 18, 2013 · Engine, Fuel system · 52,490 miles · NJ

Van started running poorly suddenly, then would not run at all. After shutting down and allowing cool down time, restarted van and it would not go into gear. Ran well in park or neutral, but shifting into any gear would "clunk" and the engine would immediately quit. After 5 days of troubleshooting, traced trouble to engine PCM after reading in on-line forums about it. Found PCM wet and pins on PCM and contacts on wire harness corroded and green due to water leaking past cowl-to-body seal. The PCM connector is not sealed, so if water does drip on it, it is dripping directly onto back side of the contacts and ford did release a tsb about this issue but not a recall. Tsb says to remove some plugs from body (my van is severely rusted in one of those 2 spots), seal around clips that hold plastic cowl to body with silicone sealant and add additional weather stripping on the outer edges of cowl to try to prevent water. I had to replace my PCM. Had my wife been on the highway when this happened, there would have most certainly been an accident or injury.