2004 Ford Freestar Service and Repair Manual

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Factory-Grade Data

The 2004 Ford Freestar service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Limited Mini Passenger Van 4-Door
  • LX Base Mini Passenger Van 4-Door
  • SE Mini Passenger Van 4-Door
  • LX Plus Mini Passenger Van 4-Door
  • S Mini Passenger Van 4-Door
  • Sport Mini Passenger Van 4-Door
  • Base Mini Passenger Van 4-Door
  • SES Mini Passenger Van 4-Door
  • Base Mini Cargo Van 4-Door
  • SEL Mini Passenger Van 4-Door

Engines covered

  • 4.2L 256Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.9L 238Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Ford Freestar Recalls & Complaints

NHTSA #04V44600013/09/2004Component: WHEELS:HUB

CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB

Consequence

IF THE CRACKS WERE TO PROGRESS, THIS COULD EVENTUALLY RESULT IN WHEEL SEPARATION. WHEEL S

Remedy

DEALERS WILL REPLACE THE FRONT HUB, ROTORS, AND WHEEL BEARINGS. THE RECALL BEGAN SEPTEMBE

NHTSA #12V00600009/01/2012Component: POWER TRAIN:AUTOMATIC TRANSMISSION

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.

Consequence

THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RI

Remedy

FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. TH

NHTSA #13V08100007/03/2013Component: SEATS

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and

Consequence

In the event that the vehicle is crashed into from the rear, an unlatched seat may increas

Remedy

Ford will notify owners, and dealers will install new third row seat latch striker mountin

NHTSA #03V45700006/11/2003Component: STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.

Consequence

IF THIS LINE BECOMES DISCONNECTED, IT MAY CREATE THE POTENTIAL FOR FLUID TO COME INTO CONT

Remedy

DEALERS WILL INSPECT THE POWER STEERING LOW-PRESSURE LINE TO ENSURE THAT IT IS SEATED PROP

TSB #10205034

Safety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers - requests for recall service action

TSB #10183770

For 2004-2007 Freestar or Monterey vehicles Safety Recall 13S01 has been issued for vehicles that are operated in high corrosion areas for an extended period, where the sheet metal that supports the folding 3rd row seat latch strikers could

TSB #10109070

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

TSB #10058103

FORD/MERCURY: SAFETY RECALL REGARDING SHEET METAL SUPPORT FOR FOLDING 3RD ROW SEAT LATCH STRIKERS CAN EXPERIENCE CORROSION AND WILL COMPROMISE MOUNTING POINT CAUSING SEAT TO MOVE. MODEL 2004-07 FREESTAR, MONTEREY. *PE

TSB #10056468

FORD/MERCURY: SHEET METAL SUPPORTING FOLDING 3RD ROW SEAT LATCH STRIKERS WILL EXPERIENCE CORROSION AND COMPROMISE MOUNTING POINT FOR FORWARD PORTION OF 3RD ROW SEAT, IF VEHICLE IS OPERATED IN HIGH CORROSION AREAS FOR EXTENDED PERIOD. MODEL

TSB #10021907

ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION. *KB

TSB #10021217

POWER STEERING HOSE LEAK NEAR COOLER EXTREME COLD CLIMATE AREAS ONLY -4 DEGREES AND COOLER. *KB

TSB #10020701

ADVANCED TRACTION CONTROL SYSTEM - DURATION ACTIVATION. *KB

Showing the 8 most recent of 64 technical service bulletins on file with NHTSA.

20050713Component: UNKNOWN OR OTHERCrash reportedFire reported

MY FAMILY INCLUDING 3 SMALL CHILDREN WERE IN THE VAN TRAVELLING HOME AND MY HUSBAND WAS IN A MINOR (30 MPH) HEAD ON COLLISION WITH ONLY DAMAGE TO THE LEFT FRONT END. A FEW MINUTES

20091230Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported3 injured

NO PRIOR TRANSMISSION TROUBLE; NO WARNING OF PROBLEM ON THE DATE OF INCIDENT. DRIVING AT HIGHWAY SPEED ON THE APPROACH TO A NARROW FOUR-LANE HIGHWAY BRIDGE. THE VEHICLE'S ENGINE

20110131Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported2 injured

I HAVE A 04 FORD FREESTAR THAT CONTINUES TO HAVE TRANSMISSION PROBLEMS. IT STARTED EARLY AROUND 40K. FMC SERVICE STATED 'JUST A LEAK'. REPEAT COMPLAINTS EQUALED 'NOTHING FOUND, ETC

20170504Component: STRUCTURE:BODYCrash reported1 injured

THIS VEHICLE I RECEIVED NUMEROUS RECALLS AND HAD MANY PROBLEMS WITH THIS VEHICLE. MAJOR ELECTRICAL PROBLEMS. WHEN IT WOULD RAIN AND GET CAR WASH THE ELECTRICAL SYSTEM WOULD MALFU

Showing the 4 most serious of 1600 complaints filed with NHTSA.

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