2004 Ford Freestar defect investigations

Investigations by NHTSA’s Office of Defects Investigation that name the 2004 Ford Freestar. An investigation is how complaints can become a recall: complaints → investigation → (sometimes) TSB → recall.

• Stabilus Rear Liftgate Struts Failing
  Investigation EQ12010 · opened Sep 28, 2012 · closed Dec 31, 2012

  Please see the attached closing resume summary.It has been attached to this document as a PDF.

• Corrosion of Third-Row Seat Attachment
  Engineering Analysis EA12003 · opened Apr 23, 2012 · closed May 2, 2013 · led to recall 13V081000

  Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt stat…

• Corrosion of Third-Row Seat Attachment
  Preliminary Evaluation PE11039 · opened Dec 21, 2011 · closed Apr 27, 2012

  ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).…

• Service Jack Failure
  Preliminary Evaluation PE11033 · opened Sep 13, 2011 · closed Dec 7, 2012

  The subject vehicles (SV) are all automatic transmission, front wheel drive vehicles with hand actuated mechanical park brakes. The investigation focused on allegations that the service jack failed and caused the vehicles to fall. The subject scissors-type jack appears to fail at the slotted hinge joints where the jack…

• Engine Stalling
  Preliminary Evaluation PE10033 · opened Aug 23, 2010 · closed Jul 15, 2011

  The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the cir…

• Transmission Torque Converter Failure
  Engineering Analysis EA09016 · opened Nov 10, 2009 · closed Feb 2, 2012 · led to recall 12V006000

  On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters co…

• TORQUE CONVERTER OUTPUT SHAFT FAILURE
  Preliminary Evaluation PE09033 · opened Jul 15, 2009 · closed Nov 17, 2009

  Odi has received 227 owner complaints alleging a sudden and unexpected loss of motive power due to an internal transmission failure in the subject vehicles.of those complaints, 124 can be attributed to the torque converter output shaft splines stripping causing a sudden loss of power to the drivetrain.the remaining 103…

• Engine stalling
  Defect Petition DP09004 · opened Jun 4, 2009 · closed Sep 7, 2010

  On May 6, 2009, NHTSA received a request for a hearing through Title 49 of the United States Code, Chapter 301, Motor Vehicle Safety, Part 557. the request was in reference to vehicle owner complaint, 10266067, filed with NHTSA on April 20, 2009, which described a problem with engine stall in a model year (MY) 2004 For…