When driving our van it started to jerk and the engine light started flashing. It then stalled out on us. It was raining that day and it continued to do this. The next day when the rain stopped it quit and ran fine, but started again the minute we hit any moisture. The computer in the van also started sending error messages constantly, check brake fluid, check oil, check rear brake lights, check traction control, check doors and so on when these things were checked there were no problems with them. The engine light continued to flash so we had someone look at it and fix it. They told us the coil pak was bad and replaced it for us. The van ran fine for 1 week and then this started again. So when I went online to do some research on this I found a site on topix, complaints about Ford Freestar that had 100's of complaints about this van. Alot of people were having the same promblems and they took it to garages where they said it is a design flaw by Ford that water gets up under the engine into the PCM (computer) shorts it out and then eventually messes up the coil. We continue to have all these problems with the van, it stalls out on me in rain or any moisture. I have had the van stall while turning onto a road and my van be stuck across the road right above a dangerous curve with my youngest child and I alone in the vehicle.

- Morehead , KY, USA

2004 Ford Freestar engine control module computer die @ about 80000 miles tranmission fail at about 65000 miles defective oe conformal coating is removed from the entire ECM board including underneath chips and replaced with upgraded conformal coating; corrects an oe design flaw and ensure chips will not lift from the board causing the unit to fail.

- Lawrence, MA, USA

While driving in the rain the van started to jerk and cut out. Stalling on occasion. We had the coil pack replaced and this repair lasted for 1 week then it started all over again. When it is dry outside the check engine light stays on but the van drives fine. As soon as it starts to rain or we hit any moisture or mud puddle the van starts jerking again and sometimes back fires or even stalls out while driving and has to be restarted. We have found that this is a problem that alot of 2004 Freestar owners are having that the PCM or computer gets wet and causes this problem due to a flaw in the design.

- Morehead, KY, USA

I bought the vehicle used in 2008. When traveling at approximately 60-70 mph the vehicle will suddenly jerk as if it's turned off and back on. This occurs 2-3 times on every highway trip of 15-20 miles. This also happens on shorter trips 2-3 times a week. When I start the vehicle the radio automatically turns on and resets the stations and digital clock. The battery seems to have trouble keeping a charge. Overnight the battery may weaken and the vehicle will fail to start. After the failed start all the needles on the control panel dials will vibrate and create a "clicking/ticking" noise which ends after 3-6 seconds. Subsequently, a jump-start is required to start the vehicle. I cannot afford expensive diagnostics so I simply keep jumper cables handy and plan around trips that may leave us stranded without assistance. I have maintained routine service like oil/fluid changes and have not had any reports on a defective battery. All indications point to a defective PCM (powertrain control module). I've done some personal research and found this to be an underlying problem for many issues affecting the 2004 Ford Freestar minivans. This problem has not been fixed. Due to the projected cost estimates of more than $1000 to diagnose and resolve, I cannot afford to have a mechanic work on it.

- Lagrange, KY, USA

We recently purchased a 2004 Ford Freestar and have had nothing but problems with it. Let it be clear from the start that I am in fact a Ford guy! but what has transpired is absolutely ridiculous and I am to the point where I do not know if I will purchase another Ford. So a week after purchasing the vehicle, the transmission + computer went out. My wife tried starting it and it would not go anywhere. I towed it to macke Ford and had them fix it. Paid $3800 for them to fix these two things. A week later it rained extremely hard and the van failed on my wife as she was driving and was luckily on a gravel road with no one around her. She was able to coast to a complete stop but again the van would not go into reverse or drive. Had it towed to macke Ford in coon rapids, ia again and they thought it was a bad PCM. I made it clear to the service dept that I thought water was getting into the PCM compartment due to other people complaining about this on the internet and the fact that it had rained extremely hard that morning. They did not think this was the case and put another PCM in and sent the other one back to Ford as they thought they received a bad PCM. Took it home and the next morning it would not start and the battery was dead. Tested and found that the radio was turning on by itself and draining the battery...even w/out the key in the ignition. Macke tried fixing it for the next 2 months and even after denying water was getting into it..finally called and said they found water in the PCM compartment and it was a Ford engineering problem. They wanted me to pay for the computer this time since Ford would not cover the water damage!! another $700. With all the internet complaints about there about water getting into the computer this should be recalled and our money returned!

- Bayard, IA, USA

Purchased this 2004 Ford Freestar 6 months ago with 98,000 miles on it from oak motors on w. 3th street in indianapolis. Every time it rains, the vehicle stopped on me. Finally, I suggested that this dealership take the vehicle to a Ford dealer to diagnose the problem as the selling dealership did not know how. I also suggested my fear in going through a car wash. The Ford dealer takes the car through a car wash and determines it is the #1 and #3 coil pack, plugs and wires. While trying to take the vehicle back in for the repair after haggling with the selling dealer about who should pay, the vehicle demonstrated what seemed like transmission failure. The selling dealership today told me that a transmission specialist informed them today that it is not a transmission problem but they think it is a problem with the van's computer system. It will not go forward or backwards but it is not a transmission problem. Also, every time it rains, the breaks squeak but when the weather is dry, breaks demonstrate no problem. Almost phantom problems. Please help. Ongoing problem since less than 30 days after purchase date of 9/31/2009.

- Indianapolis, IN, USA

For the first 16 months of ownership my Ford 2004 Freestar sel was in the shop 15 times for electrical failures. Even the dealership tried to get the van returned under the lemon law and Ford refused. I had also complained about vibration at highway speeds, and told all was normal until I demanded they check the front brake and then was told they were bad. At about 65,000 miles my transmission suddenly and without any warning went out. I was just leaving the intersection and fortunately I was not rear ended. Now just last month, December 2009 it was discovered my right rear brake caliber has been dragging for some time as the inside brake pad was worn down to the metal. Left side was fine.

- Grayslake, IL, USA

Electrical system had to be replace, Ford said it was a design flaw.

- Petersburg, NJ, USA

Vehicle purchased used with 62,000 miles in May 2006. Frequent & random dash warning lights coming on & off for no reason--including transaxle, brake, emissions system light, etc. Radio will turn on & off without the keys in the vehicle. Mechanic says that there was some moisture in PCM & that PCM does not look original. Vehicle has lost power without warning while driving several times & then 'recovered' with no warning lights on. Transmission 'went' in driveway without warning. Needed approx. $1500 in repairs to transmission. Mechanic says failing part includes pump shaft & veins. Also reconditioned pump slide & seals.

- North East, PA, USA

Engine stalling, electrical problems, traction control system disengages, and cruise control will not engage. All problems are intermittent and occur during or after rain. Problems linked to PCM water intrusion. Today entire electrical system failure.

- Franklin, TN, USA

The contact owns a 2004 Ford Freestar. While driving approximately 35 mph on normal road conditions, the idle speed increased and the vehicle accelerated unexpectedly. Suddenly, the vehicle stalled. The engine restarted and resumed normal operation. In addition, the vehicle failed to operate intermittently when shifted into reverse. The engine warning light illuminated on the instrument panel and remained lit until the engine was turned off. The vehicle was taken to an authorized dealer for inspection and they stated that water was leaking from the front windshield, which damaged the computerized system. The vehicle was repaired. On a separate occasion, the vehicle was taken to an authorized dealer and independent mechanic for identical failures. The vehicle is in the process of being repaired. The failure and current mileages were 58,000.

- Milddletown, DE, USA

The contact owns a 2004 Ford Freestar. The contact started the ignition and placed the gear shifter into drive. The engine began to rev and the transmission immediately locked up. The contact had to make several attempts before the vehicle would operate. The vehicle was towed to an authorized dealer for diagnostic testing. The technician repaired the vehicle. In addition, the rear brake assembly failed, which was not covered under the warranty. The vehicle was taken to an independent mechanic for repairs. On a separate occasion, the vehicle was taken to an authorized dealer for identical failures. The vehicle also experienced electrical failures relating to the exterior lighting. The technician recommended that the transmission be rebuilt or replaced. The vehicle has not been repaired. The failure mileage was 250 and current mileage was 52,000.

- Fort Meade, MD, USA

We own a 2004 Freestar that has had the transmission replaced in Feb 2008 with less than 43,000 miles on it. In July 2008 we spend $450 on repairing part of the breaking system, and this week the van would not go into reverse and did not have any pull to it when it finally did after several attempts. Once I got out of the parking space, I got an estimate of a block and onto a busy highway, only to have the van stall on me, almost causing a wreck. The dealership and Ford paid for the transmission to be replaced, we paid for the caliper, drum, rotor, and break pad to be replaced on the front driver side brake. When having the van checked out this week, we were told yesterday that they did diagnostics on it, and the only thing that came back was a cam sensor and that there was probably moisture involved that would cause the stalling. Nothing was repaired, and this could happen again, esp during the winter months, when winter driving is already dangerous. There is also an issue with the track control. It works most of the time but not all of the time. The light comes on at least 2 time per month. The reason can't be found for it. Ford needs to be made to do recalls on these vans for the safety of the owners.

- Tell City, IN, USA

I can not believer the number of complaints on the internet about the Ford Freestar's malfunction! there are 430 messages on edmunds.com alone on the one subject, but yet nothing has been done about it. If we want the workers in the U.S. car industry to have jobs, then they should resolve the issues and make their customers happy!!

- Westerville, OH, USA

Wife's van. Reported that in cold weather it would start hard. Recently while driving to work it bucked several times. Was able to get to work. Informed me of the problem where I went to check van. It wouldn't start after 5 attempts, then it started up but was a hard start. At the same time check engine light came on. Decided to tow it to dealer. Flat bed came but couldn't get to van. To assist in positioning van for flatbed; van started on first try but now when it was put into gear, it didn't move. Either forward or reverse. We pushed it into position. Took to dealer where now it went into gear to offload it from flat bed. Dealer stated when they depressed the brake, all dash lights lit up. Stated it was a dead short they had to trace the wiring. Received call 2 days later, dealer telling me they have to drop the transmission. Which they did, I saw it on a stand, stripped of all inner components. Was told since it's under warranty (26,000 miles), they are going to replace everything that looks remotely wrong. Been a week and still waiting for answers.

- Bluffton, SC, USA