2005 Ford Freestar Brakes Problems

THEIR IS 5 RECALLS ON MY VAN THAT I PULLED UP ON NHTSA AND THE FORD COMPANY IS SAYING THEIR IS ONLY ONE RECALL AND I'M HAVING SERIOUS ISSUES WITH THIS VAN AND I WAS DRIVING THIS VAN AND IT IS LOSING POWER WHEN DRIVING IT. I NEED UR HELP PLEASE. MY NUMBER IS (XXXXX) PLEASE LEAVE ME A MESSAGE SO I CAN CALL U BANK THANKS REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11233431

Incident

Jul 4, 2019

Mileage

166,678 mi

TL* THE CONTACT OWNS A 2005 FORD FREESTAR. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE ACCELERATED. THE CONTACT STATED THAT THE BRAKES DID NOT WORK AND THE RPMS INCREASED TO 3,000. THE CONTACT SHIFTED THE GEAR SHIFTER INTO NEUTRAL AND STOPPED THE VEHICLE. THERE WAS NO WARNING INDICATOR ILLUMINATED. THE DEALER WAS NOT CALLED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 131,000.

NHTSA ID

11113295

Incident

Jul 23, 2018

Mileage

131,000 mi

I HAD RECEIVED A LETTER OF RECALL OF MY BACK ROW SEAT LATCH DO TO CORROSION. I HAD TAKEN MY VAN IN TO BE REPAIRED THEY INFORMED ME THAT THEY WOULD HAVE TO ORDER THE PARTS WHICH TOOK 2 WEEKS UPON RETURNING THEY INFORMED ME THEY NEED ANOTHER PART THEY FORGOT TO ORDER SO I WAITED FOR MY CALL BACK AGAIN.. WITHIN 2 MONTHS TIME I RETURNED TO HAVE IT WORKED ON THAT IS WHEN THEY HAD TOLD ME IT HAD BEGUN TO CORRODE N THAT THEY COULDN'T INSTALL THE PARTS I ASKED THEM ABOUT THE SITUATION FURTHER & IF IT WAS SAFE TO DRIVE THEY HAD SAID YES & HANDED ME MY KEYS SO UPON LEAVING THE DEALERSHIP I HAD STOPPED FOR FOOD ON MY WAY HOME I SMELT BURNT RUBBER THEN A THUDDING NOISE I HAD PULLED OVER TO CHECK IT OUT LUCKILY I WAS TO CLOSE TO A FAMILY MEMBERS HOUSE A PIECE HAD FALLEN OFF N WAS RUBBING ON MY TIRE MY TIRES HAD ALMOST CAUGHT FIRE WHEN LUCKILY I HAD GOTTEN THE BABY OUT BEFORE ANYTHING HAD HAPPENED THE NEXT DAY A MECHANIC HAD INFORMED ME A HOLE WAS BURNT THREW THE FLOOR WHERE THE WHEEL WELLS WERE N THE TIRES ALMOST CAUGHT FIRE HE SAID HE COULD WELD THE PARTS SO FRENCHIES FORD COULD FIX WHAT THEY HAD TO FIX .. THE NEXT DAY HE INFORMED ME HE HAD LOOKED UP THE PARTS N CAME ACROSS THIS WEBSITE STATING IT HAD BEEN RECALLED I HAD TOLD HIM WHAT HAPPENED & INFORMED ME TO TAKE LEGAL MATTERS DUE TO FAULTY PARTS . PLEASE DON'T ALLOW THIS TO HAPPEN TO ANYONE ELTS THE THOUGHT OF MY BABY BEING IN THE BACK SEAT WHILE IT COULD HAVE CAUGHT FIRE IS TERRIFYING I WOULDN'T WANT TO HEAR OF IT HAPPENING TO ANOTHER UNDER THE SAME CIRCUMSTANCES ESPECIALLY A CHILD . & NOW THAT THERE'S A HOLE IN THE FLOOR I'M UNCERTAIN WHAT TO DO I HAVEN'T DROVE IT SINCE & QUITE HONESTLY I'M AFRAID TO .. P.S IS THIS COVERED? WHOSE @ FAULT? WHAT CAN BE DONE?

NHTSA ID

10734670

Incident

Jul 10, 2015

VEHICLE CONTROL CENTER STATES ABS IS NOT FUNCTIONING. TRACTION CONTROL NOT FUNCTIONING. CRUISE CONTROL WORKS INTERMITTENTLY. ALARM SYSTEM TRIGGERS INTERMITTENTLY. ABS AND TRACTION CONTROL FAILURE CAUSES VEHICLE TO BE DIFFICULT TO DRIVE. DEALERSHIP STATES IS COMMON ISSUE AND THERE IS A TSB ON THE ISSUE. REQUIRES ABS MODULE AND HCU MODULE. *TR

NHTSA ID

10629850

Incident

Sep 1, 2014

Mileage

72,000 mi

TL* THE CONTACT OWNS A 2005 FORD FREESTAR. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 10 MPH, THERE WAS A LOUD NOISE COMING FROM THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRONT HUB, ROTORS, AND WHEEL BEARINGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 80,000.

NHTSA ID

10595728

Incident

May 2, 2014

Mileage

80,000 mi

TL* THE CONTACT OWNS A 2005 FORD FREESTAR. THE CONTACT STATED THAT WHILE EXITING THE DRIVEWAY AT UNKNOWN SPEEDS, THE ODOMETER FAILED TO TRACK SPEED AND THE ABS WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS WHERE IT WAS STATED THAT THE SPEED SENSOR AND BATTERY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE PROBLEM PERSISTED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 57,000.

NHTSA ID

10534471

Incident

Jul 1, 2013

Mileage

57,000 mi

THE LEFT REAR CALIPER FROZE AND WORE OUT THE BRAKE AND ROTOR. THEN IN 2012 THE LEFT REAR CALIPER FROZE AND WORE OUT BRAKE AND ROTOR. AS WELL AS THE RIGHT REAR CALIPER. *TR

NHTSA ID

10459720

Incident

Oct 9, 2007

Mileage

47,000 mi

TL* THE CONTACT OWNS A 2005 FORD FREESTAR. THE CONTACT NOTICED THAT THE TRACTION CONTROL WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THAT THE ABS SYSTEM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 49,000. THE DEALER REPLACED THE HYDRAULIC CONTROL UNIT AND ABS MODULE. UPDATED 06/22/12*JB

NHTSA ID

10458342

Incident

Dec 16, 2011

Mileage

49,000 mi

WAS ON A VERY BUSY HIGHWAY. THE FREESTARS DASH LIGHTS LITE UP AND WENT BACK OFF. AC CUT OFF THEN EVERYTHING STARTED WORKING AGAIN. ABOUT 30 SECONDS LATER THE FREESTAR DIED AT 65. I WAS ABLE TO COAST TO A STOP ON THE SHOULDER. AGAIN ON MAY 5 2012 THE LIGHTS STARTED FLICKERING AND THE AC STARTED TO BLOW HARD AND IT WOULD SLOW BACK DOWN THEN THE DASH LIGHTS ABS,BRAKE,BATTERY LIGHTS WOULD BLINK ON AND OFF THEN THE FREESTAR DIED AGAIN AT 70 MPH. BRAKES DIDN'T WORK I WAS GOING THROUGH A INTERSECTION AND HAD TO USE THE E BRAKE. FREESTAR HAS DONE THIS SEVERAL TIMES OVER THE LAST MONTH I JUST HIT THE HIGH SPOTS. IT HAS HAD TEST AFTER TEST AND I'M ALWAYS TOLD A DIFFERENT STORY! I JUST WANT MY VAN FIXED BEFORE SOMEONE GETS HURT OR KILLED. *TR

NHTSA ID

10457578

Incident

Apr 1, 2012

Mileage

98,000 mi

PER FORD SERVICE: WATER IN PCM 5/03/11 SIMILAR PROBLEM 7/15/10 ALTHOUGH AT THE TIME FORD SERVICE WAS UNABLE TO FIND THE CAUSE. AT ABOUT 20 MILES PER HOUR WHILE MAKING A RIGHT HAND TURN THE ENGINE STALLED, THE POWER STEERING AND POWER BRAKES FAILED CAUSING ME TO TEMPORARILY LOSE CONTROL AND SWERVE INTO THE ON-COMING LANE. LUCKILY THERE WAS NO TRAFFIC OR PEDESTRIANS THERE AT THE TIME. FORD SERVICE FOUND THE CAUSE TO BE WATER IN THE POWERTRAIN CONTROL MODULE (PCM).

NHTSA ID

10400102

Incident

May 1, 2011

Mileage

25,437 mi

VAN STALLS AT LIGHTS. JUST CUTS OFF. MECHANIC SAID IT HAS SOME THING TO DO WITH THE PCM. TRANS HAS BEEN REPLACED. BUT STILL HAVING PROBLEMS WITH THAT. REAR BRAKE CALIPERS CEASED UP . THIS VAN IS A ROAD HAZARD. NEVER KNOW WHAT IT IS GOING TO DO OR WHEN IT IS GOING TO FAIL . *TR

NHTSA ID

10363051

Incident

Jul 15, 2010

Mileage

50,000 mi

I HAVE A 2005 FREESTAR SPORT VAN. WHEN IT IS RELATIVELY HOT OUTSIDE AND I'VE DRIVEN FOR ABOUT AN HOUR OR SO, THERE IS THIS LOUD SQUEALING NOISE COMING FROM THE FRONT OF MY VAN. IT IS VERY ANNOYING AND GETS LOUDER WITH TIME TRAVELED. I'VE TAKEN THIS VAN BACK TO THE DEALER FROM WHERE IT WAS PURCHASED. THEY'VE REPLACED THE BRAKE PADS SAYING THAT THIS COULD BE THE PROBLEM. IT DIDN'T CHANGE, THE SQUEALING KEPT COMING. THE MECHANIC SAID THAT HE HAD DONE SOME FORM OF RESEARCH THROUGH THE INTERNET AND THINKS IT COULD BE THE WHEEL BEARING. WHAT A SCARE THIS IS!!!!! HAS ANYONE HAD THIS SAME PROBLEM?? THE GARAGE WILL NOT DO ANYTHING ABOUT IT UNTIL I CAN BRING IT IN WHILE IT IS STILL SQUEALING SO THEY CAN TAKE IT FOR A ROADTEST. IT'S BEEN A YEAR SINCE I'VE BOUGHT THIS VAN FROM A REPUTABLE GARAGE IN CAMBRIDGE, ONTARIO. I'M SCARED TO GO ANYWHERE WITH IT ESPECIALLY WITH MY GRANDCHILDREN IN THE VAN WHEN WE GO ON HOLIDAYS. IS THERE A GREAT CONCERN HERE????----------PLEASE EMAIL ME BACK WITH SOME INFO TO [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10336742

Incident

Jun 2, 2009

MY CAR IS A FORD 2005 FREESTAR. IT IS EXPERIENCING INTERMITTENT BRAKE FAILURE. THE PEDAL GOES TO THE FLOOR AND DOES NOT RESPOND EVEN IF I PUMP THE BRAKES, THEN, GOES BACK TO NORMAL. I HAVE HAD IT LOOKED AT BY FORD 2 TIMES, GOODYEAR ONE TIME AND MEINEKE ONCE AS WELL. FORD COULD NOT DUPLICATE AND SENT THE CAR AND US HOME. THEY SAID THE DO NOT "WANT TO THROW PARTS AT IT". THEY SAID THEY CHECKED THE MASTER CYLINDER, THE BOOSTER AND ALSO FOR AIR IN THE LINE, BUT ALL CHECKED OUT OKAY. I CALLED THE EXECUTIVE OFFICES OF FORD. THEY SAID THEY WOULD CALL THE DEALER, THAT WE SHOULD "LEAVE IT WITH THE DEALER" BUT THEY CANNOT HELP US WITH TRANSPORTATION. I HAVE A SON WITH A BRAIN INJURY. THIS CAR IS OUR ONLY FORM OF TRANSPORTATION. PLEASE HELP. *TR

NHTSA ID

10318786

Incident

Mar 11, 2010

Mileage

158,000 mi

I OWN A 2005 FORD FREESTAR MINIVAN. THIS AUGUST MY INSTRUMENT PANEL QUIT WORKING. I TOOK IT TO THE DEALERSHIP AND WAS ADVISED THAT MY ABS MODULE FAILED AND AS A RESULT IT MELTED MY WIRE HARNESS. I JUST DISCOVERED THAT FORD PREVIOUSLY HAD THIS PROBLEM WITH THEIR WINDSTARS. I'D LIKE THIS TO BE LOOKED INTO AS THIS IS A HEFTY REPAIR ($3,000.00 +) THAT I CANNOT AFFORD. AS A RESULT, I AM DRIVING IN A VEHICLE WITH NO ABS AND NO WORKING INSTRUMENT PANEL - INCLUDING SPEEDOMETER. THANK YOU. *TR

NHTSA ID

10300432

Incident

Aug 15, 2009

Mileage

150,000 mi

TL*THE CONTACT OWNS A 2005 FORD FREESTAR. IN THE SUMMER OF 2008 HE NOTICED THAT THE VEHICLE SURGED AND SHUT OFF WHEN HE ATTEMPTED TO PARK AT LOW SPEEDS. THE DEALER DIAGNOSED THE FAILURE AND DETERMINED THAT THE THROTTLE BODY FAILED; HOWEVER, THE PART IS ON BACK ORDER. HE ALSO STATED THAT THE REAR CALIPERS WERE DEFECTED AND THAT THEY WERE UNABLE TO REPAIR THEM. THE VEHICLE IDENTIFICATION NUMBER WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 45,000 AND THE CURRENT MILEAGE WAS 59,000.

NHTSA ID

10283875

Incident

Jun 1, 2008

Mileage

45,000 mi

TWICE OUR 2005 FORD FREESTAR EXPERIENCED WATER LEAKAGE THROUGH THE COWL GRILL ON THE HOOD. AFTER HEAVY RAIN IN MARCH 2008, THE FIRST OF SEVERAL BREAKDOWNS AND FIX ATTEMPTS OCCURRED, RESULTING IN 3 MONTHS OUT OF SERVICE, AND REPLACEMENTS OF THE WIRING HARNESS, THE PCM COMPUTER, SEVERAL OTHER COMPUTERS AND SENSORS, AND THE ENTIRE TRANSMISSION, EQUALING NEARLY $5,000 IN TOW, RENTAL CAR, AND REPAIR BILLS--SOME OF WHICH THE DEALERSHIP TALKED MY INSURANCE TO PAY FOR AS A "WATER DAMAGE CLAIM." IN BETWEEN, WE'VE HAD MULTIPLE ELECTRICAL SYSTEM PROBLEMS AND BREAKDOWNS, AND THEN THIS PAST MARCH 2009, ALSO DURING HEAVY RAIN, THE CAR EXPERIENCED THE WATER DAMAGE BREAKDOWN. THIS TIME THE WATER ONLY RUINED THE PCM COMPUTER, BUT THE DEALERSHIP REFUSED TO HONOR THE REPAIRS THAT WERE LESS THAN 12 MONTHS OLD AND WE TOOK IT TO A PRIVATE LICENSED REPAIR TECHNICIAN. HE FOUND THE TECHNICAL SERVICE BULLETIN ONLINE THAT DESCRIBED THE KNOWN WATER LEAKAGE PROBLEM IN SOME 2005 FREESTAR MODELS AND DID THE RECOMMENDED FIX TWICE. IN HIS OPINION AND IN THE GEICO INSURANCE ADJUSTERS OPINION, THIS IS A SERIOUS PROBLEM THAT FORD NEEDS TO ADDRESS. THIS TIME WE HAD NO COVERAGE FOR THE DAMAGE AND WERE OUT OF A VEHICLE FOR TWO MONTHS AND OUT OF POCKET OVER $3,000. I'VE BEGGED FORD'S CORPORATE OFFICES TO TAKE THE VEHICLE BACK AND JUST LET ME OUT OF THE FINANCING BUT THEY REFUSE DUE TO THE NUMBER OF MILES. ALSO, THE ATTORNEY GENERAL'S LEMON LAW OFFICE SAID THERE WERE TOO MANY MILES. IN ADDITION TO THESE PROBLEMS, IN 90,000 MILES, I'VE HAD TO REPLACE THE ROTORS NOW FOUR TIMES BECAUSE THEY ARE WARPING DANGEROUSLY. THE PADS ARE OK, BUT THE ROTORS ARE CONTINUALLY WARPING AND IT COSTS $800 EACH TIME TO HAVE THE BRAKES FIXED. *TR

NHTSA ID

10272435

Incident

Mar 8, 2008

Mileage

66,000 mi

THE REAR BRAKE ROTORS AND PADS KEEP WEARING OUT EXTREMELY FAST. I JUST HAD THE BRAKES DONE NOT QUITE A YEAR AGO AND NOW THE ROTORS ARE COMPLETELY WORN OUT. *TR

NHTSA ID

10234103

Incident

Jul 13, 2008

TOOK MY 2005 FORD FREESTAR MINIVAN WITH ONLY 43,223 MILES INTO FORD DEALER FOR ANNUAL SAFETY INSPECTION. ADVISED BOTH REAR CALIPERS WERE BAD, CAUSED PREMATURE WEAR OF BREAK PADS AND ROTORS WHICH NEEDED TURNED. THE REPAIR COST ME $581.40. I HAVE OWNED MANY VEHICLES, AND NEVER HAVE I HAD CALIPERS FAIL AT 43K MILES. I BELIEVE THIS TO BE A MANUFACTURER DEFECT THAT I AS A CONSUMER HAD TO FOOT THE BILL FOR. I DO NOT HAVE THE PARTS. *TR

NHTSA ID

10230219

Incident

Jun 6, 2008

Mileage

43,223 mi

I TOOK MY CAR IN FOR A ROUTINE OIL CHANGE AND TIRE ROTATION. (WHICH I DO EVERY 5K, THIS WAS AT ABOUT 40K). REAR DRIVER BRAKE PADS WERE DOWN TO 10%, ALL OTHERS WERE FINE. WHEN REPLACING PADS, THE MECHANIC FOUND BRAKE FLUID HAD LEAKED INTO THE CALIPER, CAUSING IT TO FAIL. THE CALIPER FAILURE CAUSED OVERHEATING AND DRAGGING OF THE CERAMIC BRAKE PAD ON THE ROTOR, CUTTING A HUGE GROOVE INTO ROTOR, WHICH NEGATED ANY CHANCE OF MACHINING. THE CALIPERS, ROTORS AND BRAKE PADS ALL REQUIRED REPLACEMENT WITH LESS THAN 40K MILES ON THE CAR... BIG $$$$. THIS FAILURE SEEMED PRE-MATURE, AND WAS UNUSUAL EVEN TO A SERVICE MANAGER WITH MANY YEARS OF EXPERIENCE. (HE SUGGESTED THAT FORD SHOULD BE NOTIFIED, WHICH THEY WERE, TODAY, 11/26/2007). *TR

NHTSA ID

10209934

Incident

Nov 23, 2007

Mileage

39,900 mi

2005 FORD FREESTAR GRINDING BEGAN BACK BRAKES HAVE HAD VAN MAINTAIN AT DEALERSHIP SINCE GOT NEVER HAD REPORT BRAKES NEED REPLACED AS NOISE INCREASED AT 42,068 MILES TOOK BACK TO DEALERSHIP FOUND BACK BRAKE AND ROTORS NEED REPLACED BUT NOT FRONT BRAKE THIS GOOD THIS IS A FWD VEHICLE FRONT BRAKES SHOULD GO FIRST FORD REPLACED ROTORS AND PADS WANTED 475.00 BUT AFTER POINTING OUT NEVER ADV ANY PROBLEM FINAL PRICE PAID 332.01 AFTER CHECKING MAINTENANCE HISTORY IN COMPUTER CHECKING INTERNET MULTI PROBLEM BACK BRAKES HAVE CONTACT CORP FORD WILL NOT ASSIST OR RECALL ISSUE AT MOMENT THIS IS HUGE SAFETY PROBLEM ORIGINAL BACK BRAKES ARE DEFECTIVE. *JB

NHTSA ID

10203689

Incident

Sep 19, 2007

Mileage

42,068 mi

AT APPROXIMATELY 28,000 MILES WE HEARD A TERRIBLE SQUEALING NOISE COMING FROM THE REAR OF OUR 2005 FORD FREESTAR MINIVAN AND AFTER VISUAL INSPECTION THE BRAKE PAD ON THE DRIVER'S REAR WAS WORN TO NOTHING. IMMEDIATELY TOOK THE VAN TO THE DEALER WHERE THEY INFORMED US THAT IT WAS NORMAL WEAR AND WOULD NOT BE COVERED BY OUR WARRANTY. UPON FURTHER INSPECTION BY OUR PERSONAL MECHANIC WE WERE INFORMED THE CALIPER WAS STICKING AND CUT INTO THE ROTOR. HE PUT A SET OF BRAKE PADS ON SO WE COULD DRIVE IT BACK TO THE DEALER WHERE WE BOUGHT THE VEHICLE, SUNSET FORD, IN GRAVOIS. WE WERE TOLD SINCE WE DID NOT USE MOTOCRAFT THE REPAIRS WOULD NOT BE COVERED. NOW AT 50,000 MILES THE PROBLEM STILL EXISTS AND THE VAN NEEDS ANOTHER SET OF BRAKES AND ROTORS. *TR

NHTSA ID

10202249

Incident

Jun 1, 2006

Mileage

28,000 mi

AT APPROX. 33,000 MILES STARTED EXPEIENCING BRAKING PROBLEMS- SOFT PEDAL, REQUIRING EXCESS PRESSSURE TO STOP SAFELY. OCCASIONAL INSTANCES OF ACCELERATION WHILE BRAKING BECAUSE ACCELERATOR PEDAL AND BRAKE PEDAL WERE AT SAME HEIGHT. A NARROW ACCELERATION MISS DROVE ME TO MY SERVICE SHOP WHERE I ASKED THEM TO CHECK OUT THE BRAKES. THE PADS & ROTORS WERE IN FINE SHAPE. BUT THE MASTER CYLINDER PROVED TO BE BAD. IT TOOK 4 REPLACEMENT CYLINDERS FROM LOCAL DEALERS TO GET ONE THAT FIT AND FUNCTIONED PROPERLY. NOW AT 54,000 MILES THE PEDAL IS AGAIN SOFT AND BRAKING IS GETTING HARDER EACH DAY. VISUAL INSPECTION OF PADS AND ROTORS SHOW PLENTY OF USEFUL LIFE REMAINING. SINCE WHEN IS 30,000 MILES AN ACCEPTABLE AVERAGE LIFE FOR A MASTER BRAKE CYLINDER?

NHTSA ID

10191699

Incident

Nov 21, 2006

Mileage

34,595 mi

I RETURNED FROM A CROSS COUNTRY TRIP AND HEARD A GRINDING NOISE COMING FROM THE REAR OF MY 2005 FORD FREESTAR. TO INVESTIGATE I REMOVED THE WHEELS AND FOUND THE PASSENGER REAR ROTOR AND DISC PAD WERE METAL TO METAL. I CHECKED THE OTHER WHEELS, THEY SHOWED NO SIGNS OF DAMAGE, PADS STILL HAD A LOT OF MATERIAL REMAINING. I TOOK THE VEHICLE TO CRAIG FORD, IN CRAIG, COLORADO FOR REPAIRS. AT FIRST I WAS TOLD THAT IT WAS A DEFECTIVE BRAKE CALIPER AND THAT WARRANTY WOULD COVER THE CALIPER, ROTOR AND PADS. HOWEVER I WAS TOLD LATER THAT THE CALIPER WAS NOT DEFECTIVE AND THAT I WOULD BE RESPONSIBLE FOR THE TOTAL REPAIR COSTS. NOTE, I HAD LESS THAN 30,000 MILES ON THE VEHICLE AT THE TIME OF THE BRAKE FAILURE. I HAD TO PAY FOR THE NEW ROTOR FOR THE PASSENGER REAR, REAR PADS AND TURNING THE DRIVER REAR ROTOR WHICH I WAS TOLD IS A NORMAL PROCEDURE FOR E REAR BREAK JOB; I WAS NOT CHARGED FOR A CALIPER SO I PRESUME CRAIG FORD REUSED THE CALIPER. SINCE WORK WAS BEING DONE ON THE REAR, AND I WAS HAVING TO PAY FOR THE REPAIRS, I INSTRUCTED CRAIG FORD TO DO A COMPLETE BRAKE JOB REPLACING PADS AND TURNING ROTORS ON THE FRONT AS WELL SO THAT I WOULD BE STARTING AGAIN WITH 100% NEW BRAKES ON ALL 4 WHEELS. WHEN I PICKED THE VEHICLE UP, I WAS ADVISED BY THE SERVICE MANAGER, ROB SOVINE, THAT HE CHECKED AND THERE APPEARED TO BE A NUMBER OF INCIDENTS OF 2005 FORD FREESTAR PASSENGER REAR BRAKES WEARING PREMATURELY, WITH NO KNOW REASON FOR THIS PROBLEM; AND THAT THERE WAS NO RECALL OR SERVICE BULLETIN REGARDING THIS PROBLEM. I HAD NO CHOICE BUT TO PAY FOR THE REPAIRS AS THE VEHICLE WAS INOPERABLE, BUT SINCE I WAS NOT THE ONLY OWNER EXPERIENCING THIS PROBLEM, ACCORDING TO MR. SOVINE, I FELT AND STILL DO FEEL THAT FORD SHOULD DO SOMETHING ABOUT THIS PROBLEM. *NM

NHTSA ID

10180720

Incident

Oct 30, 2006

Mileage

27,673 mi

REPEATED SPONGY BRAKE PEDAL..SOMETIMES GOES TO FLOOR ON SUDDEN BRAKING. RANDOM 'SQUEAL AND SQUEAK' FROM FRONT BRAKES. ACCORDING TO SERVICE MGR. AT ORANGE FORD-LINCOLN IN ORANGE, TEXAS, THIS IS COMMON SINCE ASBESTOS WAS REMOVED FROM PADS ABOUT 4 YEARS AGO. VERY IRRITATING AND DANGEROUS. *JB

NHTSA ID

10173519

Incident

Nov 9, 2006

Mileage

9,200 mi

BRAKE PEDAL WHEN PUSHED HARD GOES TO THE FLOOR. BRAKE PEDAL WHEN PRESSED NORMAL HAS A SPONGY FEEL TO IT. ALMOST RAN INTO THE BACK END OF A CAR THAT WAS STOPPED AT A STOP SIGN BECAUSE I WAS EXPECTING THE VEHICLE TO STOP WHEN I APPLIED THE BRAKES BUT THE VEHICLE CONTINUED UNTIL I PRESSED THE BRAKE PEDAL HARD. VEHICLE MAKES HORRENDOUS NOISE "POPPING SOUND" WHEN THE ABS SYSTEM IS ENGAGED. THIS POPPING SOUND HAPPENS EVERY TIME BETWEEN 30 -45 MILES PER HOUR DURING A "HARD' BRAKE SITUATION. THESE INCIDENTS HAVE BEEN REPORTED TO THE DEALER ON 3 OCCASIONS BUT THE DEALER SAID THE ABS SYSTEM AND BRAKES CHECKED OUT OK ACCORDING TO FORD'S SPECIFICATIONS. *JB

NHTSA ID

10153768

Incident

Aug 22, 2005

Mileage

5,186 mi