2004 Ford Freestar Service and Repair Manual

This factory service and repair manual for the 2004 Ford Freestar opens the minivan's listing with nine trims and two body styles, a four-door mini passenger van and a four-door mini cargo van. Two overhead-valve V6 gasoline engines are covered, the 4.2L of 256 cubic inches and the 3.9L of 238 cubic inches, both naturally aspirated. They share an architecture but not their specifications, so the manual gives each its own torque values and clearances while the transmission, chassis and body sections serve both.

Engines covered

• 4.2L V6 (256 cu in) — OHV, naturally aspirated, gasoline
• 3.9L V6 (238 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 4-door mini passenger van
• 4-door mini cargo van

Trims covered

• Base
• Limited
• LX Base
• LX Plus
• S
• SE
• SEL
• SES
• Sport

Known issues on the 2004 Freestar. Five recalls are on federal record. The weightiest covers a torque converter output shaft that may fail and take away motive power with no warning. Another concerns third row seats that may sit unlatched, raising injury risk in a rear impact, and a third a power steering low-pressure line that can come loose and put fluid onto the exhaust. Front wheel hubs that were not heat treated correctly can crack and let a wheel separate. Owners have filed 1,227 complaints with NHTSA, overwhelmingly about the power train, and transmission and wheel-end procedures are central here.