2005 Ford Freestar

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

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 states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.

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 screw is located (bends at mid-point). The failures occur while the jack is in use, and vehicle movement (forward or backward) is typically reported coincident with the failure. Ford reported that most MY 2003 Windstar and all MY 2006-2007 Freestar/Monterey also use the subject jack, an additional 223,246 vehicles.NHTSA has received six consumer complaints (VOQs) involving three injury incidents and a fatality.Ford reported 26 complaints for the SVs involving an additional 4 injuries. In the fatal incident, the van fell on a person working on the engine under the otherwise unsupported vehicle; ODI was unable to determine whether the vehicle was adequately chocked or the park brake was properly set. Reported injuries include a broken arm, head and hand injuries, arm and rib bruises, and muscle strains. NHTSA has received just one new report since opening this investigation. The complaint trend in ODI and Ford data is flat if not declining.Ford provides instructions and warnings in the owner's manual, on a placard placed with the jack, and on the jack itself. These instruct consumers to put the vehicle gear selector in Park, properly set the parking brake, chock the opposite wheel, use the jack only for changing a tire, loosen the lug nuts prior to jacking, and to not get under a vehicle supported by the jack only (NHTSA also recommends that jacks only be used for tire changing).In the VOQs, roughly half the consumers were using the jack for something other than tire changing, half had not chocked a wheel, and half had not properly set the parking brake. ODI notes that since the front wheels are drive wheels (with an open center differential) the Park gear cannot provide vehicle stability (longitudinally) when a front wheel is raised. All NHTSA complaints and most of the complaints to Ford involved failures while a front wheel was raised.In response to ODI's inquiry, Ford conducted testing on a 2004 Freestar. Ford's tests showed that when a front tire was raised the service jack held without failing under various scenarios except when a rocking force was applied and the parking brake was not properly set. Based on its testing and its analysis of field data, Ford concluded that the type of jack failure evidenced in this investigation (bending at mid-point) was likely caused by vehicle movement due to an improperly secured vehicle, or other misuse of the jack. Ford notes that rates in this investigation were similar to those in another investigation (EA91-049) which ODI closed. ODI also analyzed jack data for MY 2003 and newer vehicles to compare to the SV population. To assist with this analysis, ODI requested data from the jack manufacturer (actually its successor company) who provided limited data but did identify other models using the same design jack. ODI was unable to identify a significant difference in the incidence of jack failures (including those involving bending failures) between the SVs, other vehicles which used the same jack, or other vehicles where the jack type was unknown or different.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, investigation PE11-033 is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist and ODI reserves

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 circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.

When I was driving my van was loosing power even when I was pushing the gas I had to pull over before a car was about to hit me. I look it up online it had a recall in 2013 but I bought van from someone last year and I called the ford place about the recall and they said couldn’t do it Mac hik in Jackson

NHTSA ID

11742615

Incident

Jun 3, 2026

The contact owns a 2005 Ford Freestar. The contact stated that the third-row seat attachments were rusted. The vehicle was taken to the dealer to be repaired under NHTSA Campaign Number: 13V081000 (Seats); however, the part to do the recall repair was not yet available. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 317,000. Parts distribution disconnect.

NHTSA ID

11674191

Incident

Jun 17, 2025

Mileage

317,000 mi

The contact owns a 2005 Ford Freestar. The contact stated that while driving at an undisclosed speed, the transmission seized and remained in neutral. The vehicle jerked and shortly returned to normal functionality; however, the failure persisted. The contact stated that the gear shifter light was illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure became a recurring failure, and the contact parked the vehicle, and the vehicle was no longer driven. The contact related the failure to NHTSA Campaign Number: 12V006000 (POWER TRAIN); however, the VIN was not included. The failure mileage was unknown.

NHTSA ID

11660471

Incident

Apr 12, 2025

The contact owns a 2005 Ford Freestar. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. The contact stated that the vehicle stopped in the middle of the street, however the engine was still on. The contact stated that the gear shifter did not function as intended. The contact stated that the gear shifter did not shift. The contact was able to coast the vehicle to the shoulder of the road. The contact and her son pushed the vehicle to the nearest parking lot. The vehicle was not diagnosed or repaired by an independent mechanic. The manufacturer was not made aware of the failure. The failure mileage was unknown.

NHTSA ID

11620383

Incident

Oct 10, 2024

I was driving and my transmission stopped working left me stranded

NHTSA ID

11597284

Incident

May 26, 2024

The contact owns a 2005 Ford Freestar. The contact stated while driving 70 MPH and releasing the accelerator pedal, the contact noticed an abnormal clucking sound. The contact stated that upon depressing the accelerator pedal, the vehicle failed to respond. The contact pulled to the side of the road. The contact stated he was able to continue driving; however, the failure persisted. The contact stated that upon depressing the accelerator pedal, the vehicle only responded when the RPMs were high, and the vehicle failed to exceed 30 MPH. The vehicle was taken to an independent mechanic, where it was diagnosed that the torque converter output shaft had failed. The mechanic determined that the torque converter and the output shaft needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The contact related the failure to NHTSA Campaign Number: 12V006000 (Power Train). The manufacturer was notified of the failure and informed the contact that they could not assist because the vehicle was previously repaired under the recall. The failure mileage was approximately 350,000.

NHTSA ID

11595095

Incident

Jun 14, 2024

Mileage

350,000 mi

The contact owns a 2005 Ford Freestar. The contact stated that upon selling the vehicle, she allowed another individual to test drive the vehicle; however, as the contact was driving on an incline, the vehicle stalled. The vehicle was taken to the dealer where it was diagnosed that the flex shaft had failed. The contact then stated that upon research, she became aware of NHTSA Campaign Number: 12V00600 (Power Train). The vehicle was not repaired. The contact stated that she received notification of the NHTSA Campaign Number: 13V081000 (Seats). The vehicle was taken to the dealer where the contact was informed that due to the condition of the vehicle the recall repair could not be performed. The contact was concerned that when the vehicle was taken to the dealer, the VIN was entered and displayed a different color. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 180,000.

NHTSA ID

11532243

Incident

Nov 11, 2022

Mileage

180,000 mi

The rear wheel well has rusted on both sides and completely rusted out a large hole (approx. 1 ft diameter area visibly effected) in the the body of the van. The rusted out section is where the back seat is anchored to the frame, so the rust has cause the seat to no longer be securely anchored to the car. The hole has also caused electrical wires to get wet when water gets into the van and intermittently and unpredictably causing failure of electrical features, including headlights and blinkers, while driving.

NHTSA ID

11511200

Incident

Mar 10, 2023

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 when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.

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

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 experience corrosion and may compromise the mounting point for the forward portion of the 3rd row seat. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the front of the seat when in its seating position. If corrosion is severe, the seat latch strikers may become detached from the vehicle. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected.

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

REAR CLIMATE CONTROL NOISES - SERVICE TIP. *TT

RESTRAINT CONTROL MODULE DIAGNOSTIC TROUBLE CODE B2296 - SERVICE TIP. *TT