2007 Ford Freestar

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 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.

ON OCTOBER 14, 2008, ODI OPENED PE08-060 TO INVESTIGATE ALLEGATIONS OF CRACKED AND LEAKING SNAP-IN TIRE VALVES IN MODEL YEAR (MY) 2007 VEHICLES MANUFACTURED BY FORD MOTOR COMPANY.THE VALVES WERE SUPPLIED TO FORD BY TOPSEAL AUTO-PARTS, A SUBSIDIARY OF THE SHANGHAI BAOLONG AUTOMOTIVE CORPORATION IN CHINA.VALVES MADE BY TOPSEAL FOR AFTERMARKET SALE WERE THE SUBJECT OF TWO RECENT SAFETY RECALLS BY TECH INTERNATIONAL (08T-018) AND DILL AIR CONTROLS (08T-028), THE LATTER OF WHICH WAS INVESTIGATED BY ODI IN PE08-036 AND EA08-022.THE DEFECT CONDITIONS ADDRESSED BY THE AFTERMARKET TIRE VALVE RECALLS BOTH INVOLVED INADEQUATE RESISTANCE TO OZONE CRACKING DUE TO ISSUES WITH THE SUPPLY OF ANTI-OZONANT CHEMICALS TO TOPSEAL FOR A PERIOD FROM JULY TO MID-NOVEMBER 2006.THE AFTERMARKET VALVES WERE COMPOUNDED WITH A BLEND OF EPDM AND NATURAL RUBBER, USING A RELATIVELY LOW PERCENTAGE OF EPDM (EPDM PROVIDES INHERENT RESISTANCE TO OZONE CRACKING).HENCE, THE NEED FOR ANTI-OZONANT CHEMICALS AND THE PROBLEMS WITH CRACKING WHEN THOSE CHEMICALS WERE MISSING OR OUT OF SPECIFICATION IN SOME LOTS OF VALVES.BOTH RECALL CAMPAIGNS INVOLVED INSPECTION PROGRAMS TO IDENTIFY AND REPLACE VALVES WITH VISIBLE SURFACE CRACKING.ALTHOUGH THE TOPSEAL VALVES SUPPLIED TO FORD ALSO APPEAR TO HAVE BEEN AFFECTED BY THE ANTI-OZONANT SUPPLY ISSUES IN MID TO LATE-2006, FORD INDICATED THAT ITS VALVES WERE MADE AT A DIFFERENT TOPSEAL PRODUCTION LINE AND WERE COMPOUNDED WITH A HIGHER PERCENTAGE OF EPDM RUBBER TO MEET MORE STRINGENT SPECIFICATIONS FROM FORD.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA PROVIDED BY FORD SHOWED THAT PROBLEMS WITH CRACKED TIRE VALVES WERE SIGNIFICANTLY HIGHER FOR MY 2007 VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007.FORD RESPONDED BY IMPLEMENTING CHANGES IN ITS MATERIAL SPECIFICATIONS FOR SNAP-IN RUBBER TIRE VALVES AND ALSO INCREASING THE QUALITY AND ACCEPTANCE STANDARDS FOR VALVES IMPORTED FOR USE IN ITS VEHICLES.WHILE THE COMPLAINT AND WARRANTY CLAIM RATES ARE ELEVATED FOR SUBJECT VEHICLES PRODUCED FROM DECEMBER 2006 THROUGH MARCH 2007, THE RATES OF LEAKING VALVES ARE WELL BELOW ONE PERCENT OF PRODUCTION FOR EACH OF THE PEAK MONTHS FOR ALL OF THE AFFECTED MODELS.A SUBSTANTIAL MAJORITY OF THE SUBJECT VEHICLES ARE EQUIPPED WITH TIRE PRESSURE MONITORING SYSTEMS (TPMS) WHICH WARN THE DRIVER WHEN ANY TIRE PRESSURES DROPS BELOW 25 PERCENT OF RECOMMENDED INFLATION PRESSURE. AS OUTLINED IN A LETTER TO ODI DATED APRIL 6, 2009, FORD HAS AGREED TO SEND LETTERS TO OWNERS OF CERTAIN MY 2007 AND 2008 FORD, LINCOLN AND MERCURY VEHICLES TO PROVIDE INFORMATION ABOUT THE CRACKING CONCERN. LETTERS WILL BE SENT TO OWNERS OF VEHICLES BUILT FROM NOVEMBER 2006 THROUGH MAY 2007.OWNERS CAN OPT FOR A FREE DEALER INSPECTION.VALVES EXHIBITING SURFACE CRACKS OR AIR LEAKAGE RELATED TO OZONE ATTACK WILL BE REPLACED BY FORD UNDER ITS NORMAL WARRANTY TERMS.FORD EXPECTS TO SEND THE LETTER BY APPROXIMATELY MID-MAY 2009. BASED ON THE USE OF TPMS IN THE MAJORITY OF SUBJECT VEHICLES AND THE RELATIVELY LOW RATES OF REPAIRS ASSOCIATED WITH LEAKING VALVES AND RESULTANT TIRE DAMAGE, ODI BELIEVES THAT THE ACTIONS FORD HAS AGREED TO TAKE WILL PROVIDE EFFECTIVE AND EXPEDITIOUS RESOLUTION FOR VEHICLES THAT WERE BUILT DURING THE PERIOD WHEN VALVES WITH INADEQUATE RESISTANCE TO OZONE CRACKING WERE MOST LIKELY TO HAVE BEEN USED IN VEHICLE PRODUCTION.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.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

The contact owns a 2007 Ford Freestar. The contact received notification of NHTSA Campaign Number: 13V081000 (Seats); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. The VIN was unavailable.

NHTSA ID

11616056

Incident

Sep 15, 2024

The contact owns a 2007 Ford Freestar. The contact stated that he discovered two large holes located on both sides of the third-row seats. The contact stated that the holes were located at the seat anchors; the structural degradation at the seat anchor were mounted to the rear wheel wells. The contact then discovered that his vehicle was placed under NHTSA Campaign Number: 13V081000 (Seats). The contact then notified the dealer and was informed that the part to repair the vehicle was not available and also that the corrosion on the vehicle was too severe to complete the repair. The manufacturer was also notified of the failure and referred the contact to the Better Business Bureau for further assistance. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the repair. The failure mileage was approximately 100,000. Parts distribution disconnect.

NHTSA ID

11462138

Incident

Apr 1, 2022

Mileage

100,000 mi

PASSENGER SIDE MIRROR BURNED, SMOLDERED WITH A GREAT DEAL OF SMOKE. COULD SEE ORANGE GLOW BEHIND THE MIRROR. SMELLED LIKE AN ELECTRICAL BURN. CAR WAS PARKED, NO KEY IN IGNITION, HAPPENED RIGHT AFTER UNLOCKING CAR WITH KEY FOB.

NHTSA ID

11163095

Incident

Dec 16, 2018

Mileage

68,000 mi

TORQUE CONVERTER IS SHOWING SIGNS OF FAILURE WITH VAN A LESS THAN 50K MILES. A TRANSMISSION FLUSH AND SERVICE INCLUDING FORD'S FRICTION MODIFIER DID NOT FIX.

NHTSA ID

11124495

Incident

Aug 4, 2018

Mileage

57,000 mi

TL* THE CONTACT OWNS A 2007 FORD FREESTAR. WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED AS THE ACCELERATOR PEDAL WAS DEPRESSED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 89,000. *JS

NHTSA ID

11115445

Incident

Jun 13, 2018

Mileage

89,000 mi

TL* THE CONTACT OWNS A 2007 FORD FREESTAR. WHILE THE VEHICLE WAS BEING REVERSED WITH PASSENGERS SEATED IN THE THIRD ROW, THE THIRD ROW SEAT ATTACHMENT BOLT FRACTURED. THE CONTACT STATED THAT THE SEAT SHIFTED AND WAS NO LONGER SECURELY FASTENED TO THE SUBFRAME OF THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED OR REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA ID

11109689

Incident

Jul 4, 2018

Mileage

150,000 mi

I HAVE A 2007 FORD FREESTAR SE. VIN# [XXX]. AT 102,296 MILES THE TRANSMISSION FAILED. I WAS DRIVING IT ON A SIDE STREET AT APPROXIMATELY 15 MILES PER HOUR. I WAS ACCELERATING FROM A STOP SIGN, WHEN THE TRANSMISSION APPEARED TO SLIP INTO NEUTRAL. I LOOKED AND IT WAS STILL IN DRIVE, I TRIED DOWNSHIFTING, PUTTING IT INTO NEUTRAL AND BACK INTO DRIVE AND NOTHING WORKED. I COASTED TO THE SIDE OF THE ROAD AND PUT IT INTO PARK. THAT APPEARED TO WORK. I THEN TRIED USING REVERSE AND IT DID NOT ENGAGE. I THEN TRIED ALL GEARS AND NOTHING HAPPENED. I THEN HAD THE VEHICLE TOWED TO MY HOUSE. I LET IT COOL DOWN AND IT STILL DID NOT WORK. THE TRANSMISSION FLUID IS A CLEAN PINK AND SMELLS BRAND NEW. I PROCEEDED TO DO ONLINE RESEARCH TO DETERMINE THE PROBLEM AND IF IT CAN BE EASILY REPAIRED, WHAT I FOUND WAS VERY INTERESTING. IT WAS A VERY COMMON PROBLEM OCCURRING AROUND 103,000 MILES. MANY (HUNDREDS IF NOT THOUSANDS OF PEOPLE HAD THE SAME ISSUE WITH THIS VEHICLE SPANNING SEVERAL YEARS, MOST NOTABLY FROM 2004 THROUGH 2006. THERE WAS A RECALL ISSUED FOR THOSE YEARS. THERE WAS NOT, HOWEVER, A RECALL FOR THE 2007 MODEL YEAR. THERE ARE NUMEROUS PEOPLE WITH THIS YEAR AND PROBLEM AS WELL. I AM CURIOUS AS TO WHY THE 2007 MODEL YEAR WAS NOT INCLUDED WHEN IT OBVIOUSLY SUFFERS THE SAME ISSUE.. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11080128

Incident

Feb 27, 2018

"TAKATA RECALL" WHILE DRIVING MY VAN I LOST TO GO TO THE BANK, WHEN I WENT TO PUT MY FOOT ON THE GAS PEDAL IT WOULD NOT GO. THERE WAS NO MOVEMENT. IT MADE THIS FUNNY SOUND UNDER THE HOOD. I HAD NO WARNING, IT SHIFTED GEARS, MY HUSBAND EVEN PLUGGED IN THE CODE READER AND NOTHING CAME UP. AS WE ARE LOOKING INTO THE ISSUE THE TORKE CONVERTER WENT OUT IN THE TRANSMISSION. SO NOW THIS NEEDS TO BE REPLACED. WE WE'RE ON A IT STREET AT A STOP LIGHT GETTING READY TO MAKE A LEFT HAND TURN.

NHTSA ID

11056992

Incident

Dec 22, 2017

Mileage

141,000 mi

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.

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.

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

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

DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X, ROUGH IDLE, ENGINE KNOCK/PING ON ACCELERATION. *NJ

ADVANCED TRACTION CONTROL SYSTEM - DURATION ACTIVATION. *KB