2004 Ford Freestar: fuel pump failure

Filed Mar 15, 2013 · Electrical, Engine · 153,500 miles · IN

Our 2004 ford freestar stalled, and then surged after accelerating from a stop. The next day the check engine light came on. We took it to a local ford dealer, capital city ford in indianapolis, who in indicated the code was for a fuel pump problem. We paid over $800 to have the fuel pump replaced on december 27th. In late february the van began to stall and surge again. We suspected the same problem. It continued to do this off and on for the next two weeks and on march 8th the check engine light came on again. We took it back to the same ford dealer and they said the initial code was for the same error, but when another mechanic/technician checked the code it came up with a different problem. We were advised that the there was "moisture" getting into the PCM causing the problem and not only was it causing the engine to stall, but was giving wrong error codes. The replacement of the PCM was estimated to be a +$1,000 cost. We were advised that it "seemed to be" a design flaw in the location of the PCM in that it is in line with the waterflow from the windshield. After much research on the internet on this issue, it appears it is a long-standing issue with many owners of this vehicle and even with replacement of the PCM the problem will happen again due to the design flaw. The safety risk related to engine stalls due to the failure of the PCM is unacceptable. The failure of the dealership to identify this well-known problem and charge us for a repair (fuel pump) that was unnecessary is unconscionable.

Filed Sep 18, 2012 · Electrical, Engine · 107,812 miles · NJ

Van won't start thought it was fuel pump had it towed & replaced cost $500 van starts then shuts off mechanic said PCM malfunction dealer should fix it! Help ford stand by there vehicle! Complain.

Filed Apr 12, 2012 · Transmission · 87,133 miles · AK

While driving my 2004 ford freestar 4.2 litre ,at speed of 60mph on highway suddenly vehicle stalled , and I had to act fast and coasted vehicle 2 lanes over to hug shoulder of highway. Put vehicle in park turn ignition off turn the key over vehicle starts fine I drive back on the highway vehicle drives good like nothing occurred, my thought was fuel line problem, so had mechanic look at it he changed my fuel pump , fuel filter, fuel pressure sensor , so back on the road with vehicle , vehicle keeps stalling at 50-60mph and also stalls at traffic stop light while idling. Having done some research online my problem seems like ford motor company has a defect problem in the PCM (powertrain control module)with the ford freestars/mercury monterey models it sold. I believe now my vehicle is not safe to drive and endangers other drivers on the road. Please look into this systematic problem with ford freestars/monterey minivans.

Filed Apr 22, 2011 · Electrical, Fuel system · 88,842 miles · PA

This is the second issue I have had with water getting into the PCM(computer). The first occurrence (03/10) I had the car towed to the ford dealership and was advises per the obdb scan codes that the transmission needed an overhaul. I told the dealership that I had just pulled the car out of my driveway and had no reverse and had slippage in other gears, it was raining very heavily that day- I asked the dealership if it could be an issue of moisture getting into PCM(computer), the dealership said that that was not the issue. I then had the car towed to a reputable transmission repair shop, there I was told that my car was the third to freestar to have been brought in with an issue of water getting into the PCM(computer). The owner of the transmission shop was able to let the PCM dry out for three days and reinstall with no transmission issues. The second event (04/11) happened after several days of rain; while driving to work the instrument panel displayed the following lights: check engine, brakes, ABS, fuel, battery, and trans axle light. The vehicle stalled out in the middle of traffic, and I had the car towed back to my mechanic who advised that the fuel pump and fuel pump module was defective and replaced. However, the trans axle light was still appearing intermittently. I took the vehicle back to transmission shop for second time, and through careful trouble isolation, they determined that the pcu was telling the torque converter to shift into fourth gear while coming to a stop. They allowed the pcu to dry out, but then determined that the transmission module had shorted out and that it need to be brought to dealership to reprogram pcu. I contacted the dealership who stated that they are not aware of any moisture/water issues with freestars and I advised them that I am filing a complaint the federal safety agency and will also forward letter to ford motor company.

Filed Apr 13, 2011 · Electrical, Transmission · 88,820 miles · PA

Repeated problems with moisture/rain getting into PCM(computer). Car is back at transmission shop again due to car stalling during braking. I have had fuel pump/module replaced in error, due to false check engine codes due to moisture/rain getting into PCM, owner of transmission said issue is with water in PCM causing torque converter to engage during braking.

Filed May 20, 2010 · Transmission · 80,000 miles · PR

Tl* the contact owns a 2004 ford freestar. The contact stated while driving uphill at speeds of 15 MPH, the vehicle became stuck in neutral. The dealer advised the failure was due to transmission fluid contamination. The transmission fluid solenoids and fuel pump were replaced. The failure recurred within one year and the contact was unable to shift the gear shift selector in drive or reverse. The vehicle was towed to the dealer where they again, found transmission fluid contamination and the exact repairs were performed from the previous year. The failure did not persist however; the contact was concerned that the failure would recur. The failure mileage was 80,000 and the current mileage was 106,050.

Filed Jan 12, 2010 · Transmission · 100,839 miles · MT

I own a 2004 ford freestyle mini van. While driving and without any prior warning the van came to a sudden stop in traffic and would not shift into gear. I was very lucky that an accident was barely avoided. I had it towed to a mechanic and was told that the transmission had failed and that it was unusual to have a transmission fail in a vehicle with under 100,000 miles. He also informed me that he had seen this happen in many other 2004 freestyle vans. The mechanic noted that the transmission failed due to the fuel pump working incorrectly and as well as the failure of the torque converter thus contaminating the entire transmission. The entire transmission had to be replaced. After reading about the numerous transmission failures and the road hazards they have caused I am extremely upset that ford has failed to take responsibility for the problems with there product.