2004 Ford Freestar suspension problems

Filed Jun 17, 2019 · Body, Electrical · 212,000 miles · OH

Tl* the contact owns a 2004 ford freestar. While the vehicle was undergoing routine maintenance by an independent mechanic, the contact was informed that the control arm was protruding through the frame and created a hole. In addition, the check engine indicator illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and did not assist. The failure mileage was approximately 212,000. *bf consumer stated transmission just started to slip and makes a thud sometimes slips bad. Consumer has changed the transmission oil and filters.

Filed Mar 18, 2019 · Suspension, Transmission · 270,000 miles · AR

Tl* the contact owns a 2004 ford freestar. The contact stated that the transmission did not function properly. The lever was heavy and became stuck before switching into gear. Sometimes, the vehicle hesitated and made an abnormal whining sound. Also, the axles made a crunching and grinding sound whenever the vehicle made a turn. The transaxle warning indicator illuminated. The vehicle was taken to an independent mechanic, but the mechanic did not have the equipment to repair the transmission. The contact was informed that the cbs axles needed to be repaired. The manufacturer and dealer were not made aware of the failures. The vehicle was not repaired. The failure mileage was 270,000. ..*bf consumer took the vehicle to the transmission shop and was told the sudden power could be torque converter but needs to checked. Common failed transmission error.

Filed May 22, 2016 · Electrical, Suspension · 16,462 miles · OH

Problem #1 the passenger side window will not work . It's controll module was replaced it worked one time and stopped working again. Problem #2 the drive axle broke in traffic luckily we were stopping and were only going about 5 MPH. Problem #3 today after a night of heavy rain when the van was unlocked the radio came on before the key was even in the ignition. Which brings us to problem #4 the biggest and no doubt most expensive. The van started and was running kind of sluggish but ran fine in reverse but if you shift to drive the van shuts off. You cannot start it in neutral either. I have had 2 independent mechanics look at it today both say it is the torque converter. I looked it up and there is a recall but of course it's the weekend and I can't call to see if it's covered.

Filed Jan 31, 2016 · Suspension · MI

The front subframe is severely corroded. Mechanic says it's unsafe to drive. Ford recalled 425,000 1998-2003 ford windstars for the same problem. It doesn't appear the problem was corrected.I don't want to wait for it to fail before it's reported and I can't, in good conscience, sell it someone else. Is there anything I do to rectify this?

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 Apr 6, 2015 · Body, Suspension · 141,000 miles · CA

First crack in u shaped steel channel noticed when I took this van in for other recall repairs at yucca valley ford . They notified me and I had it welded . A few months later crack was back had it rewelded and gussets added to restrengthen both sides. Lasted six months till I took to tire shop to have front end aligned and two new tires put on. Left next day for gig broke one mile from home just past the weld. This van has always been a california car to my knowledge. No rust. Same rear axel as windstar. Bad design. Van is heavy little [xxx] steel channel to hold all that weight is stupid. Couldn't believe it was built that way. How come no recall for same axel design on freestar. People apt to die from this stupid design. *tr information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Jan 7, 2015 · Suspension · 155,000 miles · NJ

Tl-the contact owns a 2004 ford freestar. The contact stated that while an independent mechanic was servicing the vehicle, it was discovered that there were cracks on the rear axle. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 155,000. Djr

Filed Jul 17, 2014 · Suspension · 120,000 miles · ME

Tl* the contact owns a 2004 ford freestar. The contact stated that there was a loud abnormal noise coming from the front end of the vehicle. The vehicle was taken to an independent mechanic, who replaced the stabilizer arm and the front brakes but the failure persisted. The vehicle was taken for a state inspection when it was noticed that the bushings around the ball joint was cracked and the bolt fractured within the lower control arm. The inspector also indicated that the frame needed to be replaced and the vehicle was unsafe to drive. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 120,000. Updated 08/19/14*lj updated 08/24/2017

Filed May 19, 2014 · Suspension · 76,000 miles · PA

Tl* the contact owns a 2004 ford freestar. While the vehicle was parked, the contact noticed that the front passenger side wheel was positioned inward. The vehicle was towed to a mechanic, who stated that the front lower control arm became completely detached from the vehicle. The vehicle was being repaired. The manufacturer was not notified. The VIN was unavailable. The approximate failure mileage was 76,000.

Filed Jun 18, 2013 · Body, Suspension · 170,214 miles · MA

I had my vehicle to the ford dealership on a recall for the third row latch/corrosion issue. While in the process of doing the repair, the service dept. Found massive undercarriage corrosion, in which other parts of my car were disintegrating & falling apart, such as the starter and the engine mounts, as well as parts of my exhaust system. While my car was on the premises there were also two other freestars with similar amounts of massive corrosion on the body of the vehicle, particularly all of the doors. My vehicle is only 9 years old and has been taken care of with regular maintenance and should not look 20 years old with the corrosion that it has accumulated. I also have a large, visible crack in my wheel well in the rear passenger area caused by corrosion and my vehicle may not pass inspection. I have been in touch with ford motor co. And they seemed only casually interested, but did give me a case file # [xxx]. They report that there is currently no recall on any of the peripheral corrosion problems and could not guarantee that there would be a recall on this. The supervisor at the dealership expressed to me that he has seen at least 6-8 other freestars with the same corrosion in the same places. My car is rotting from the inside...presently when it rains, my front passenger door accumulates water inside, which eventually drains itself out through the corrosion underneath that panel. Please help me to force a recall on this issue so that I can get my car repaired in an appropriate manner and feel safe in driving without worrying that my vehicle will disintegrate underneath me from this massive corrosion problem. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).