Ford Freestar knocking problems

Filed Jan 23, 2021 · 20 miles · IN · fire

I just came across this website and wish I wrote this a year ago because I would have made a complaint then. I have had many issues with the lights flickering, coming on automatically when it rains, my interior lights staying on and actually catching fire because it had gotten so hot. My radio used to turn on by itself or not turn on at all, which has now been replaced. My van has literally died on me while driving more often at times when I'm making a turn or slightly moving my steering wheel. Has almost caused a few accidents because it shuts off without warning. My van will usually have a higher RPM when it's running in park or with foot on break(waiting at a red light). Then suddenly the rpms drop and fluctuate high and low and shut the engine off. My transmission is also starting to fail by not shifting properly. Usually into second gear. The indicator lamp light flashes with means error with the transmission. That is most likely due to the power train automatic transmission torque converter getting wet or it is powertrain automatic transmission. Also have issues with my my power steering the wheel knocks and sorta locks up at times , fluids have been checked and were perfect. I believe that it's associated with the steering hydraulic system failure.

Filed Aug 31, 2020 · Transmission · 128,310 miles · OH

Tl* the contact owns a 2005 ford freestar. The contact stated that while driving and accelerating, a knocking noise occurred coming from the flex plate and torque converter. The check engine warning light was illuminated. The vehicle was taken to park ford (400 west ave, tallmadge, oh 44278), and was diagnosed. The contact was informed that the torque converter and flex plate needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 128,310.

Filed Jan 3, 2018 · Transmission · 100,000 miles · MI

Vehicle was once under recall for torque converter but actual problem is water seeping into the PCM. The vehicle suddenly has shifting problems, suddenly loses all power while driving, sometimes won't go into gear at all, and knocks and shudders very intensely while accelerating. The vehicle performs all these while driving or stationary on all streets at all speeds. The problem initially it intermittent and progressively gets worse.

Filed May 14, 2014 · Electrical, Transmission · 165,000 miles · MD

Rpm's surge, loss of power while driving, already had recalls done and still having problems, trans axle light comes on when doing highway speeds., I think the recall needs to be on the electrical system and where the main computer is located. The main computer is right beneath the awning for the wiper assembly...lots of potential water damage and many unhappy customers. This is supposed to be a family vehicle and it is more like driving a ticking time bomb. I would hate to be on the highway and the vehicle just suddenly stop. Not good ford!!! Not good!

Filed Dec 26, 2013 · Transmission · 145,000 miles · FL

Took van into dealership per recall for torque converter. Received vehicle back 3 weeks later. Heard a ticking noise that progressively got worst. Made a appointment to return vehicle to dealer and the transmission completely went out as described in recall. No gear engagement in any gear forward or reverse. Of course the dealer said there was no relation to the recall and the recall was performed. Even the symptoms were exactly as described in the recall description of what would occur if the recall was not performed. Ford denied any assistance. The dealership offered us a labor discount if we purchased a transmission yet no warranty for the work unless it was a ford remanufactured transmission at 1800.00.

Filed Apr 2, 2012 · Acceleration, Engine · 127,305 miles · AR

I just received a safety recall notice 11s25 / the federal safety agency recall 12v‑006 everytime I drive my van it does not seem to want to accelerate or maintain speed. I have taken it to the mechanic and I was told that I needed to have a new egr valve put on, so I did. That did not fix the problem and I was told new spark plugs and wires so I had them replace, that did not fix the problem. Then I was told that I may need a new fuel filter, so I had it replaced and once again that did not solve the problem. This is the only vehicle I have and I am a single mom to two young children. I am worried that while I am driving I will lose all power and will be hit by another vehicle. My van never wants to go over 40 MPH and once it does reach that speed it will not maintain and sometimes makes an odd noise. I pulled onto the by-pass the other day and my van would not accelerate right away... Thank god that the truck behind me was able to pass me on the shoulder. There have been a couple other times when my van would not gain speed and I would have to pull over so that the vehicles behind me could pass. So in a nut shell the problems are as listed: 1.) van will not accelerate or maintain speed 2.) when I press on the gas pedal there is often a pinging / knocking sound I just want to know what I need to do to get this problem fixed and not be out any more money. Please help!

Filed Mar 22, 2012 · Electrical, Engine · 67,600 miles · PA

Every time it rained, my engine would shudder, shake, sometimes knock, the transmission would shift for no good reason, and I stalled out in traffic once. The vehicle became non-drivable when it rained (and only when it rained). I took the vehicle to my ford dealer (schults ford of harmarville, pa), where technician pat sand indicated that this is a known problem with ford freestars, and said a ford service bulletin indicates that because of a manufacturing problem (incorrect sealer application to the PCM and poor position of PCM in relation to windshield run-off) water leakage into the program control module causes it to issue random commands and errors. They followed the ford bulletin and by simply better sealing against moisture / blocking the water flow, resolved the problem. This is a safety issue and a known manufacturing defect.

Filed Sep 12, 2010 · Electrical, Transmission · 65,000 miles · KY

I bought the vehicle used in 2008. When traveling at approximately 60-70 MPH the vehicle will suddenly jerk as if it's turned off and back on. This occurs 2-3 times on every highway trip of 15-20 miles. This also happens on shorter trips 2-3 times a week. When I start the vehicle the radio automatically turns on and resets the stations and digital clock. The battery seems to have trouble keeping a charge. Overnight the battery may weaken and the vehicle will fail to start. After the failed start all the needles on the control panel dials will vibrate and create a "clicking/ticking" noise which ends after 3-6 seconds. Subsequently, a jump-start is required to start the vehicle. I cannot afford expensive diagnostics so I simply keep jumper cables handy and plan around trips that may leave us stranded without assistance. I have maintained routine service like oil/fluid changes and have not had any reports on a defective battery. All indications point to a defective PCM (powertrain control module). I've done some personal research and found this to be an underlying problem for many issues affecting the 2004 ford freestar minivans. This problem has not been fixed. Due to the projected cost estimates of more than $1000 to diagnose and resolve, I cannot afford to have a mechanic work on it.

Filed Aug 2, 2010 · Transmission · 102,000 miles · KS

2005 ford freestar-sudden transmission failure at highway speed. No prior warning, no knocking or sound, just a total disengagement of any gears. Vehicle still ran but could not engage any gears. It acted as if it were in neutral. This happened on an interstate and fortunately I was able to stop the vehicle prior to going over a long bridge. After reading on the internet, this has happened to countless others and I found out that an investigation was launched over a year ago by the federal safety agency. My family and I were lucky that I was able to stop prior to the bridge. I then had to have the vehicle towed about 40 miles and found out this morning that it was the transmission converter and pump shaft which will cost about $2,000 to repair.

Filed Jul 6, 2010 · Engine · 66,250 miles · KY

The manifold and tube assy which runs from my condenser to the compressor blew out while my family was driving down the highway. Prior to this in may of 2010, after the birth of my 3rd child, I was taking him to his 2 week checkup and it was pouring down rain and the windows were fogging up so bad that I had to use a paper towel to wipe the windows so that I could see out them. The A/C system has not worked properly since I have purchased my freestar in feb of 2010. There was a ticking noise before the hose blew and before we could figure out where it was coming from the hose and all our freon was a cloud of white behind us. We have taken our van to one shop which said that the condenser and evaporator was bad then took it for a second opinion where they replaced the manifold and tube assy and recharged the system. They found that the compressor was only putting out 100 lbs of pressure but should be putting out 250 lbs. They said it was safe to use (but the air would only be cool while highway driving not while stopped) until they were to replace the compressor in 3 days, and that with only 100 lbs of pressure the hose would not blow again. After less than 24 hours and maybe 3 hours of actual A/C time the hose blew again and out came all the freon. When we took the van back they were at a loss of why. I have now spent over 300 dollars that was useless and we are back at square one because noone knows why this is happening. I have read other complaints by freestar owners who have had the same problems. Before this is over I expect to spend over 1700 dollars which I don't have for a problem it seems many others have.