Ford Freestar fuel pump problems

Filed Jan 10, 2016 · 100,045 miles · OK

I am not sure where the problem lies but we suspect it may be electrical. We have had the fuel pump, fuel filter replaced, and the PCM cleaned and dried out but the van is still making a squealing noise and dies without notice, most often in the middle of a turn or at a stop light or sign. The squealing starts when you turn the van on, then will stop and start again randomly. Usually soon after it will just die. So far it has always restarted but it seems to be getting worse. We are afraid to drive it very far for fear it will die in traffic or in the middle of an intersection with oncoming traffic.

Filed Dec 1, 2015 · Fuel system · 132,000 miles · NC

I had just turned onto mebane street when the car just stopped dead. I steered it off of the road, put it in park and exited the vehicle. I waited a while and tried to start it again. It started and then sputtered and died. I called a tow truck and the driver tried to start it and it did the same thing for him. He stated it was either the fuel pump or fuel filter.

Filed Aug 6, 2013 · Transmission · 88,484 miles · TX

I have had two incidents with this van. The first incident I was driving and heard a clicking sound and then lost all power to my vehicle. I called a tow truck and took it to a mechanic who said it was the transmission which had shavings from my torque converter of my van. He stated that he had fixed transmission and torque converter in ford 2005 freestars vehicles. This was in march 2012. I had it fixed with an expenses of 1, 985, but after checking on freestars it was in the process of being evaluated. I could not wait for the resolving of this by ford. I fixed my vehicle and assumed the cost. I received a recall notice for the torque converter/transmission. I also received a recall for the back seat. Before I had a chance to take it in for repairs. On, july 30, 2013 while driving on the highway to work my van went from 65 to 20 within a matter of seconds. I placed my hazards and looked for the access road. I then drove my van into the nearest dealer. I told the dealer rep that the symbol indicated that my power train was having problems he offered to do a diagnostic for $106. I agreed and mentioned the recalls. When I received the diagnostic results stating that the fuel pump, the eg valve, and the fuel rail pressure sensor needed to be replaced.

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 Aug 19, 2012 · Electrical, Engine · 87,000 miles · FL

The van has been hard to start just recently past month it takes 4 turns of key to start , van dies while driving, battery has died . Took to ford dealership and they cant find anything wrong at all . They had me replace , fuel pump / spark plugs and wires / fuel filter/ ignition coil / tps sensor / air intake idle sensor / cleaned and reprogrammed the PCM / made new ignition key / cleaned all ground connections / checked alternator / replaced battery / drained gas tank and added fuel cleaner / after all of this expense I still am having the exact same issues ?????? Any advice from anyone ??/ thanks in advance .

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.