TroubleAtlas Score
FORD FREESTAR (2004–2007) — Technical Guide, Fault Codes & Maintenance
Built 2004–2007 · all production years covered on this single page
3.9L V6 • Gasoline
© Wikimedia Commons CC BY-SA
TroubleAtlas Score
An independent value score for the Ford Freestar (2004–2007) — reliability, safety, cost, parts, upkeep and documentation. Owing nothing to the manufacturer.
Scorecard · each voice 0–10
Reliabilityn/a
Safety & recallsn/a
Repair cost8.4
Parts & repairability5.3
Maintenance & durability6.4
Documentation & support3.9
Independent · Verified · Never for sale
Every figure on this Ford Freestar (2004–2007) page is aggregated and cross-checked against more than 6.6 million real workshop operations, NHTSA records and OEM technical sources — and updated continuously. No invented estimates.
The Ford Freestar (2004–2007) uses Motorcraft 5W-20 Synthetic Blend engine oil. Its battery is group 96R (BCI), rated at 650A cold-cranking amps. It is powered by a 3.9L V6 engine. Its OEM tyre size is 215/55 R16. Use the sections below for verified fluids, battery, OEM tyres, the maintenance schedule, recommended parts and the most commonly reported OBD2 fault codes for this vehicle.
Common problems
Common repairs
Scheduled maintenance
Fluids & lubricants
Battery
Fault codes (OBD2)
Dashboard lights
Parts comparator
Accessories & tools
Tyres
Recalls & TSB
Complaints
Workshops nearby
COMMON PROBLEMS
Engine overheatingFREQUENT
Engine temperature over limits — check coolant level, thermostat and radiator.
Related codes: P0217
Oil pressure sensor: low signalFREQUENT
ECU detects insufficient oil pressure — check oil level and sensor.
Related codes: P0522
Insufficient oil pressureFREQUENT
Oil pressure below critical threshold — stop the engine and check immediately.
Related codes: P0524
Engine control module (PCM) faultFREQUENT
Faulty ECU processor — requires specialist workshop diagnosis.
Related codes: P0606
Throttle actuatorFREQUENT
Throttle actuator motor circuit open — loss of throttle response.
Related codes: P2100
COMMON REPAIRS
Front brake pads
Difficulty: Medium
1.2h
€84 – €108
Rear brake pads
Difficulty: Medium
1.2h
€84 – €108
Engine oil change
Difficulty: Easy
0.5h
€35 – €45
ABS Module
Difficulty: Hard
2.4h
€168 – €216
AVERAGE INDICATIVE COSTS
Prices may vary by area and workshop.
Full service
€ 120 – € 200
Full brake service
€ 180 – € 300
Spark plug replacement
€ 80 – € 140
Electronic diagnosis
€ 40 – € 70
OFFICIAL LABOUR TIMES (OLP)
Standard labour hours from a database of 6.6M+ real shop operations, with an indicative labour-cost estimate for your country.
Brakes8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| ABS Module | 2.4h | € 108–€ 180 |
| ABS Pump | 2.4h | € 108–€ 180 |
| ABS Tone Ring | 1.8h | € 81–€ 135 |
| ABS Wheel Speed Sensor - Front | 1.8h | € 81–€ 135 |
| ABS Wheel Speed Sensor - Rear | 1.8h | € 81–€ 135 |
| Brake Bleed - All Four | 1.8h | € 81–€ 135 |
| Brake Booster | 3.6h | € 162–€ 270 |
| Brake Booster Check Valve | 1.2h | € 54–€ 90 |
Cooling8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Coolant Bypass Pipe | 1.8h | € 81–€ 135 |
| Coolant Flush | 0.8h | € 36–€ 60 |
| Coolant Reservoir | 1.8h | € 81–€ 135 |
| Coolant Temperature Sensor | 1.2h | € 54–€ 90 |
| Cooling Fan Assembly | 1.8h | € 81–€ 135 |
| Cooling Fan Motor | 1.8h | € 81–€ 135 |
| Cooling Fan Relay | 1.2h | € 54–€ 90 |
| Engine Oil Cooler | 1.8h | € 81–€ 135 |
Electrical8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Airbag - Driver | 1.8h | € 81–€ 135 |
| Airbag - Passenger | 1.8h | € 81–€ 135 |
| Airbag - Side | 1.8h | € 81–€ 135 |
| Airbag Module/Computer | 1.8h | € 81–€ 135 |
| Alternator | 2.4h | € 108–€ 180 |
| Alternator Belt | 1.8h | € 81–€ 135 |
| Amplifier | 1.8h | € 81–€ 135 |
| Antenna | 0.6h | € 27–€ 45 |
Engine8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Camshaft Position Sensor | 1.8h | € 81–€ 135 |
| Camshaft R&R | 5.4h | € 243–€ 405 |
| Connecting Rod Bearings | 1.8h | € 81–€ 135 |
| Crankshaft Position Sensor | 1.8h | € 81–€ 135 |
| Crankshaft R&R | 1.8h | € 81–€ 135 |
| Cylinder Head R&R | 5.4h | € 243–€ 405 |
| Cylinder Head Resurface | 5.4h | € 243–€ 405 |
| Engine Mount - Front | 3.6h | € 162–€ 270 |
Exhaust8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Air Injection Check Valve | 1.8h | € 81–€ 135 |
| Catalytic Converter - California | 2.4h | € 108–€ 180 |
| Catalytic Converter - Direct Fit | 2.4h | € 108–€ 180 |
| Catalytic Converter - Universal | 2.4h | € 108–€ 180 |
| Downpipe | 2.4h | € 108–€ 180 |
| EGR Cooler | 1.8h | € 81–€ 135 |
| EGR Tube | 1.8h | € 81–€ 135 |
| EGR Valve | 1.8h | € 81–€ 135 |
Fuel system8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Charcoal Canister | 1.8h | € 81–€ 135 |
| EVAP Purge Valve | 1.8h | € 81–€ 135 |
| EVAP Vent Valve | 1.8h | € 81–€ 135 |
| Fuel Cap | 0.4h | € 18–€ 30 |
| Fuel Filler Neck | 3.6h | € 162–€ 270 |
| Fuel Filter | 1.2h | € 54–€ 90 |
| Fuel Filter - In-Tank | 1.2h | € 54–€ 90 |
| Fuel Injector - Single | 3.6h | € 162–€ 270 |
HVAC8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| AC Accumulator | 2.4h | € 108–€ 180 |
| AC Clutch Coil | 1.8h | € 81–€ 135 |
| AC Compressor | 2.4h | € 108–€ 180 |
| AC Compressor Clutch | 2.4h | € 108–€ 180 |
| AC Compressor Oil Add | 2.4h | € 108–€ 180 |
| AC Condenser | 2.4h | € 108–€ 180 |
| AC Evaporator | 2.4h | € 108–€ 180 |
| AC Expansion Valve (TXV) | 2.4h | € 108–€ 180 |
Steering8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Center Link/Drag Link | 1.8h | € 81–€ 135 |
| Electric Power Steering Module | 1.8h | € 81–€ 135 |
| Electric Power Steering Motor | 1.8h | € 81–€ 135 |
| Idler Arm | 1.2h | € 54–€ 90 |
| Pitman Arm | 1.8h | € 81–€ 135 |
| Power Steering Fluid Flush | 0.5h | € 22–€ 37 |
| Power Steering Gear Box | 2.4h | € 108–€ 180 |
| Power Steering Hose - High Pressure | 1.8h | € 81–€ 135 |
Suspension8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Air Line | 1.8h | € 81–€ 135 |
| Air Spring/Air Bag | 1.8h | € 81–€ 135 |
| Air Suspension Compressor | 1.8h | € 81–€ 135 |
| Air Suspension Height Sensor | 1.8h | € 81–€ 135 |
| Air Suspension Valve Block | 1.8h | € 81–€ 135 |
| Ball Joint - Lower | 2.4h | € 108–€ 180 |
| Ball Joint - Upper | 2.4h | € 108–€ 180 |
| Ball Joints - Upper and Lower | 2.4h | € 108–€ 180 |
Transmission8 operations
| Operation | Labour hours (OLP) | Est. labour cost |
|---|---|---|
| Clutch Cable | 1.8h | € 81–€ 135 |
| Clutch Disc | 1.8h | € 81–€ 135 |
| Clutch Kit | 5.4h | € 243–€ 405 |
| Clutch Master Cylinder | 2.4h | € 108–€ 180 |
| Clutch Slave Cylinder | 2.4h | € 108–€ 180 |
| Flywheel Resurface | 5.4h | € 243–€ 405 |
| Kickdown Cable | 1.8h | € 81–€ 135 |
| Neutral Safety Switch | 1.8h | € 81–€ 135 |
WORKSHOP LABOUR RATES BY COUNTRY
Average independent-workshop hourly labour rates, to estimate repair costs in your country.
🇩🇪Germany€95/h
🇪🇸Spain€55/h
🇫🇷France€75/h
🇮🇹Italy€45/h
🇬🇧UK£80/h
🇺🇸USA$120/h
Reference rate
€45/h
Source: Eurostat 2024
💧 FLUIDS & LUBRICANTS
🔧 SCHEDULED MAINTENANCE
Accessory Drive Belts—
Power Steering Fluid—
Cooling System Hoses And Clamps—
Battery Performance12 months
Tire Pressure And Condition1 months
Windshield Wiper Blades—
Washer Fluid—
Body And Paint—
📋 RECALLS & TSB (6)
NHTSA 04V446000
Wheels › Hub
Date: 13/09/2004
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.
NHTSA 06E056000
Fuel System, Gasoline
Date: 13/06/2006
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH T…
NHTSA 06V069000
Structure › Body › Hatchback/Liftgate
Date: 09/03/2006
ON CERTAIN VANS EQUIPPED WITH THE POWER LIFTGATE OPTION, THE POWER LIFTGATE MOTOR AUTOMATICALLY DISENGAGES AFTER THE LIFTGATE IS POWERED OPEN.
NHTSA 12V006000
Power Train › Automatic Transmission
Date: 09/01/2012
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
NHTSA 13V081000
Seats
Date: 07/03/2013
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 originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Mai…
NHTSA 03V457000
Steering › Hydraulic Power Assist › Hose, Piping, And Connections
Date: 06/11/2003
ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.
COMMON OBD2 CODES TO CHECK
P0420
Catalyst System Efficiency Below Threshold Bank 1
Powertrain
P0171
System Too Lean Bank 1
Powertrain
P0300
Random/Multiple Cylinder Misfire Detected
Powertrain
P0441
EVAP Incorrect Purge Flow
Powertrain
P0128
Coolant Thermostat Below Regulating Temperature
Powertrain
P0455
EVAP System Leak Detected (Gross Leak)
Powertrain
P0700
Transmission Control System (MIL Request)
Powertrain
P0507
Idle Air Control System RPM Higher Than Expected
Powertrain
P0174
System Too Lean Bank 2
Powertrain
All documented fault codes for this vehicle
The most documented diagnostic codes for this model, by system and severity. Tap a code for the full guide.
P1233
powertrain
HIGHP1651
powertrain
LOWP1650
powertrain
LOWP1641
powertrain
HIGHP1579
powertrain
HIGHP1537
powertrain
LOWP1455
powertrain
MODERATEP1451
powertrain
LOWP1409
powertrain
MODERATEP1383
powertrain
MODERATEP1285
powertrain
HIGHP1270
powertrain
LOWP1237
powertrain
HIGHP1235
powertrain
HIGHP1152
powertrain
MODERATEP1117
powertrain
LOWP1116
powertrain
LOWP1103
powertrain
MODERATEP1783
powertrain
CRITICALP1746
powertrain
HIGH
DASHBOARD WARNING LIGHTS — UNIVERSAL GUIDE
57 warning lights classified by urgency. Appears on your vehicle? Check the urgency level.
Show all dashboard warning lights
🔴 IMMEDIATE STOP — pull over
Oil Pressure WarningEngine
Engine Temperature WarningCooling
Brake System WarningBrakes
Immobilizer / Key FaultSecurity
Low Oil Pressure (Ford)Engine
🟠 WARNING — check soon
Malfunction Indicator Light (MIL) / Check EngineEngine
Diesel Particulate Filter (DPF)Emissions
Battery / Charging SystemElectrical
Low Fuel WarningFuel
ABS WarningBrakes
Brake Pad Wear IndicatorBrakes
Electronic Parking Brake (EPB)Brakes
Power Steering WarningSteering
ESC / Stability Control FaultChassis
Tire Pressure Warning (TPMS)Chassis
Transmission Temperature WarningTransmission
Transmission / Gearbox FaultTransmission
Airbag / SRS WarningActive safety
EGR / Exhaust Gas Recirculation FaultEmissions
Catalytic Converter / Emissions FaultEmissions
AdBlue / DEF Level LowEmissions
Coolant Level LowCooling
Hybrid / EV System WarningHybrid
EV Charge System FaultHybrid
12V Battery (Hybrid/EV Auxiliary)Hybrid
Suspension Fault / Air SuspensionSuspension
CAN Bus / Network Communication FaultNetwork
Water in Fuel FilterFuel
Diesel Injector FaultFuel
Steering Angle Sensor FaultSteering
Turbo / Boost Pressure FaultEngine
Regenerative Braking Fault (Hybrid/EV)Hybrid
🟡 MONITOR
Fuel Cap / Evap SystemEmissions
4WD / AWD SystemDrivetrain
Bulb Failure WarningLighting
Headlight Range / Leveling FaultLighting
Service / Maintenance DueMaintenance
A/C System FaultHvac
Clutch Wear WarningTransmission
Cruise Control / ACC FaultADAS
AdvanceTrac Off (Ford)Chassis
SYNC System Fault (Ford)Electrical
🔵 INFORMATION
Engine Temperature Low (Blue)Cooling
Glow Plug / Diesel PreheatEngine
Traction Control / ESC OffChassis
Seatbelt ReminderActive safety
Rear Fog Light IndicatorLighting
Lane Departure / LDWS WarningADAS
Forward Collision Warning (FCW/AEB)ADAS
Blind Spot Monitor FaultADAS
Rear Parking Sensor / Camera FaultADAS
Windshield Washer Fluid LowMaintenance
Door Open WarningBody
Hood / Trunk Open WarningBody
Gear Shift Indicator (Manual)Transmission
Sport / Performance Mode ActiveTransmission
MyKey Speed Limit (Ford)Electrical
REPORTED COMPLAINTS & PROBLEMS (NHTSA)
2532 owner complaints filed with the U.S. National Highway Traffic Safety Administration (NHTSA) for the Ford Freestar across model years 2004–2007. These are real, verified reports submitted by vehicle owners.
29 crash reports 21 fires 41 injuries 1 death
Complaints by model year (most reported first)
Model year 20041227
Model year 2005885
Model year 2006356
Model year 200764
Most reported components (all years)
Power Train1741
Electrical System235
Engine148
Structure127
Seats119
Vehicle Speed Control99
Sample reports
JUST RECENTLY BOUGHT 05 FORD FREESTAR VAN, 3 MONTHS AGO IN MY DRIVEWAY IT REFUSED TO GO FORWARD, I PARKED IT BECAUSE I HAD SOMETHING ELSE TO DRIVE. MORNING OF DECEMBER 30, 2019 MY OTHER AUTOMOBILE TIMING CHAIN BROKE SO I'VE BEEN TRYING F… (MY 2005)
WHILE DRIVING AT HIGHWAY SPEED (75MPH) THE TRANSMISSION FAILED, THERE WAS NO WARNING AND THERE WERE NO PREVIOUS PROBLEMS WITH THE TRANSMISSION. THE TRANSMISSION HAS NO FORWARD OR REVERSE GEARS LEAVING IT ESSENTIALLY IN NEUTRAL. THIS LE… (MY 2006)
FORD TRANSMISSION IS SLIPPING OUT OF GEAR AT HIGHWAY SPEEDS. *TR (MY 2004)
WHILE DRIVING MY FORD FREESTAR I LOST POWER I WAS ABLE TO PULL OVER BUT THE VAN WOULD NOT MOVE AT THAT POINT. COULD GET THE RPM'S UP BUT WOULD NOT MOVE. THE PLACE I TOOK IT TO SAID IT SEEMS TO BE THE TRANSMISSION. I CANNOT AFFORD THIS A… (MY 2005)
Source: NHTSA complaints database (U.S. data.gov). Figures cover production years 2004–2007.
Frequently Asked Questions
Does the Ford Freestar have any safety recalls?
Yes — 6 official NHTSA recall campaign(s) affect this model, mainly: SEATS, POWER TRAIN:AUTOMATIC TRANSMISSION, FUEL SYSTEM. Check the recalls section for your exact year/VIN.
What does fault code P0003 mean on the Ford Freestar?
Fuel Volume Regulator Control Circuit Low This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
What does fault code P0002 mean on the Ford Freestar?
Fuel Volume Regulator Control Circuit Range/Performance This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
What does fault code P0001 mean on the Ford Freestar?
Fuel Volume Regulator Control Circuit/Open This code is among the most documented for this model — tap it in the OBD2 section for the full step-by-step guide.
Are electrical problems common on the Ford Freestar?
Yes — 449 of 2491 real owner reports filed with NHTSA mention the electrical. One owner reported: “The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An…” See the owner-reported complaints section below for more.
Are engine problems common on the Ford Freestar?
Yes — 720 of 2491 real owner reports filed with NHTSA mention the engine. One owner reported: “The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An…” See the owner-reported complaints section below for more.
Are transmission problems common on the Ford Freestar?
Yes — 1340 of 2491 real owner reports filed with NHTSA mention the transmission. One owner reported: “The contact owns a 2004 Ford Freestar. The contact stated while driving at approximately 40 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the residence. An…” See the owner-reported complaints section below for more.
What tyres does the Ford Freestar (2004–2007) use?
The original OEM tyre size for the Ford Freestar (2004–2007) is 215/55 R16. Compatible alternative sizes: ["225/60R16", "235/55R17", "245/45R19", "245/55R17", "235/60R16"]. See the Tyres section on this page to compare offers from the main suppliers.
What is the right battery for the Ford Freestar (2004–2007)?
The battery specified for the Ford Freestar (2004–2007) is group 65 (BCI), with a cold cranking rating of 750A. See the Battery section on this page for the main cross-references between brands.
What engine oil should I use on the Ford Freestar (2004–2007)?
The engine oil specification for the Ford Freestar (2004–2007) is Motorcraft 5W-20 Synthetic Blend. Always use the viscosity grade approved by the manufacturer: a different oil can reduce engine protection and void the warranty. Check the change interval in the Maintenance section.
Which OBD2 fault codes are commonly documented for the Ford Freestar (2004–2007)?
Commonly documented OBD2 codes across many vehicles include: P0420, P0300, P0171. Find the full description, likely causes and estimated repair costs in the OBD2 Codes section on this page.
How often should the Ford Freestar (2004–2007) be serviced?
Routine maintenance for the Ford Freestar (2004–2007) typically includes an oil change every 6,000–9,000 miles (10,000–15,000 km), an air filter every 12,000–18,000 miles (20,000–30,000 km) and a brake inspection every 12,000 miles (20,000 km). Check the full plan with specific intervals in the Scheduled Maintenance section on this page.
This spec sheet is updated with data verified from OEM sources and shop databases. If you spot an inaccuracy or have additional data on the Ford Freestar (2004–2007), let us know — every correction improves quality for all users.