Recalled torque converter replaced in 2005 Freestar by dealer. ( no warranty paperwork given for this part.) 5 months later, while driving 40 mph, experienced total power loss including power steering and power brakes. Struggled to pull car off the main road. Towed to often used and nearby repair facility. Trusted mechanic pulled car apart and replaced transmission ( including new torque converter) for total of $2225. Van had been carefully maintained and had 83,000 miles on it. Ford dealership ( tom's Ford of keyport, NJ) refused to reimburse just for cost of 2nd torque converter that failed since "the work was not done at Ford dealership." ( how would I know this was required w/out ever receiving warranty paperwork" and I remembered the original recall form from Ford stated part replacement by outside mechanics would be reimbursed??") local dealership "couldn't help." Notice, I did not even try to get Ford to acknowledge transmission failure caused by recalled part or to cover the new transmission costs. Followup through Ford's consumer division also denied reimbursement for 2nd failed torque converter. Interesting quotes from them: "we have not received many complaints about transmission failure for that vehicle" and " the failure of the torque converter does not cause transmission failure." Hmmm beware of total loss of power with this minivan when the transmission fails!!! dangerous and Ford is playing dumb. Unfortunately, lives at risk with this denial strategy. I used to be a "Ford" man. Drove only Ford for decades: F150 truck + $$$ Ford rv + Explorer + escape, etc. No longer.

- Morganville, NJ, USA

First we had the transmission failure that was unsafe and had to pay for the repair ourselves then finally Ford issued a tsb to repair and recovered our money. Along with that is the more dangerous situation of the van stopping jerking speeding up the driving on the road especially when it rains or even a slight mist. This need to addressed by the NHTSA and pressure Ford to repair this before they are sued for a death caused by the lack of attention to this highly safety related failure.

- Oak Creek, WI, USA

Driving down the road in heavy traffic, without warning suddenly had no power, at 40mph, put it in neutral and restarted only to die again 3 more times. I thought I was out of gas but the gage said 1/8th of a tank. Pulled off the road and had friends bring gas. Started up fine and drove maybe a block when it started sputtering and bucking. The check engine idiot light came on so I pulled over again. I reset the battery connection and light went off. I pulled off to drive around in the parking lot and it died when I cranked the wheel turning every corner. Started again, this time it was hard to turn over, and it sputtered and the transaxle idiot light started flashing, the radio came on by itself and the eve player ejected. Interior lights were on but switch was turned off. Checked the tranny fluid, it looked a little low in the dark(midnight) so put in half a quart. Light went out but the van refused to go forward. I dropped it manually into 1st and it slowly moved. Parked it and tried other gears, all unresponsive but when shifting into neutral the engine jumped and the rpms revved up to 3000!! afraid it would jump into gear and run over my friend, I cut off the ignition while in neutral. I waited until midnight for no traffic, then drove the van home, keeping the emergency flashers on. Was able to travel about 25 feet per restart, each time the van would die when speed exceeded 15mph or 2000rpms. Took an hour to get the 1.5 miles home. This van had just gotten a full service oil change/lube/filter service and I had the transmission serviced at sears upon purchasing it just 6 months ago and had no other issues at all. Upon researching, this is a known issue that Ford published but refuses to fix/recall. There is a recall on my van's torque converter, this is a serious safety issue and a major defect that will get someone killed or serious injured.

- Federal Way, WA, USA

Took van in to transmission repair shop because even though Ford replaced the torque converter on the recall the transmission still slipped. When repair was completed we went and picked up our van on the way home it died and all the lights were going crazy. Shop towed back to their shop. They went through van and found the computer was saturated with water. We were told need a new computer and new wiring harness and this has been a known issue with Ford with their computers getting wet. Now we are out 2600 and still don't have a car. If this is a known issue why isn't Ford doing anything to fix the issue?

- Puyallup, WA, USA

My vehicle was in the park position and when I proceeded to drive it started hesitating and would not pick up speed.

- Redford, MI, USA

After years of problems, previous postings on this site, and 3 pcms later... the story continues: Our van has been in the shop 5 times within ~ 4-5 weeks, and the dealership keeps working to seal the PCM unit. The unit was sealed by Ford with standard module seals, green expandable foam, etc., but water still got into the computer housing. During research on the Freestar's computer problems, I read about the clip slots (where the PCM fits into the van) providing a means of water intrusion also, so they took it out again and sealed those. I got the van out of the shop, and the next day the check engine light came on. We took it by an auto parts place for a scan, and it showed a PCM problem. (the guy at the auto parts store said he had a 2005 Freestar, and his PCM had shorted out also from water damage.) at least, this time a code was given! generally, codes are not generated since the malfunctioning computer is the code generator. I don't know if another PCM has shorted out in our van, or if water has once again seeped into the unit. The wet winter in Georgia has practically rendered my van useless for the past couple of months. The van is truly a "fair weather" vehicle. To find more information on this issue, google "2005 Ford Freestar PCM water intrusion" or visit any of the auto safety sites on-line such as NHTSA or arfc.org. I am currently seeking legal counsel regarding this issue, since Ford has failed to take responsibility for the problems. Unfortunately, PCM issues have often remained undetected due to the lack of code indications. (it took almost 2 years for one of many mechanics to diagnose our Freestar's issues, and that was a result of on-line research.) PCM water intrusion problems usually are manifested as transmission or engine issues such as no reverse, erratic gear changes, RPM "revs", or other unexplained occurrences.

- Jasper, GA, USA

The vehicle stalled in the middle of the road with my wife driving and two children in the car. Luckily no one was injured, my wife was able to coast the vehicle out of harms way. This could have been so much worse had she been pulling out into traffic or merging on to the interstate. The problem is the PCM module has been getting wet, Ford knows of this problem and even created a service bulletin about it. At the very, very least I would have thought Ford would have contacted the vehicle owners to make them aware that a serious issue like this existed. This has the potential to have grave consequences for innocent families owning these vehicles. It is my opinion that vans in particular should be scrutinized a little more closely due to their intended audience, soccer moms hauling around the most valuable possession of that family, their children. It is beyond me how automakers can put unsafe vehicles like this on the road and they are not forced to repair issues like these when the owners and their families are at risk. This is my second but separate complaint I lodged against Ford about this vehicle. The first one was in 2008 or 2009 when the torque converter failed without warning, leaving the vehicle lifeless in the middle of the road. This vehicle should be deemed unsafe for the roads and Ford should be forced to have a fair buy back program for these vehicles.

- Louisville, KY, USA

Trying to back out of my driveway, van will not go into reverse. Restart van, put it into reverse & it falters & stalls. Restart &got van into drive, but it will not accelerate until 3000 rpms, then jerks into drive & stalls again. Had it towed to a local mechanic I have used for over 20 yrs. Van shows no codes.replace battery, have throttle body cleaned, cam sensor is tested, shows not problems. Van starts & runs for one day. Same exact issue happens again. Have it towed a second time. Again, no codes come up.mechanic flushes out the tranny, & van runs again for 50 miles w/O incident. But again, trying to leave for work next day, van displays the exact same issues. No torque to move the van, constant stalling as soon as it is taken out of drive. Will not move at all or starts & moves very hesitantly into reverse, catches gear & jerks, stalls once again. Tow again to a Ford dealer. Told the prob is the recalled torque converter. Have it replaced, and van doesn't make it the 12 miles home. The van lost complete power on a highway & I was almost hit by oncoming traffic. Tow back, now being told the transmission needs replacement, over $3,000 because metal from the recalled part has dislogged into tranny. I am now finding thru my own research that this is a common problem relating to the PCM, which replacing tranny doesn't solve the issues. Ford is offering no help or compensation am a single mom of 2 kids, 1 is disabled, & now been fired from my job because I can't get there 28 miles away. The van is stranded at the dealer, because I have no money to fix or tow again. I am at my wits end. Ford needs to step up to the plate &replace this van!!!! repairing the torque converter, cam sensor, or transmission will not solve the PCM problem, which is not sealed properly, & after numerous repairs, will malfunction again> my Q to Ford is:does someone have to die for U to do something?

- New Port Richey, FL, USA

The contact owns a 2005 Ford Freestar. The contact stated that while driving at various speeds, the vehicle stalled and multiple warning lamps illuminated. The vehicle was taken to the dealer. The technician diagnosed that the PCM module needed to be replaced. The manufacturer was made aware of the failure but did not offer any assistance. The vehicle was not repaired. The VIN was not available. The failure mileage was 90,000 and the current mileage was 176,000.

- East Freetown, MA, USA

Engine stays in third gear on highway, windshield wiper fluid won't spray and power locks don't work with button on doors or key fob. Getting 11 miles a gallon because won't shift into fourth gear and that's a highway trip!

- Ogden, UT, USA

Difficult to diagnose! symptoms of a wet PCM module manifests itself in many forms. We've experienced most of them by this point in our ~3 year battle with our Freestar. Randomly, our van would not: Start, go into reverse, give warning lights, drive forward without stalling, allow certain systems to function properly. In other situations, it would: Run roughly, break down, rev up unexpectedly, create transmission issues, etc. Seals wear down and allows water to enter into the computer, due to its location under the windshield. One of the greatest problems of all is the lack of diagnostics for this issue. We've had our vehicle towed in, only to find diagnostic codes did not show up when the van was checked out. Surprisingly, the car would usually start up and drive without a problem after being towed into the mechanic. After several towing experiences, we simply decided to leave our car stranded for a day or two if possible and return later to drive it away without a problem. We've replaced pumps, coils, transmission components, plugs, wires.. in an effort to get the van to work properly. Finally, one mechanic did on-line research and found the PCM problem with the 2005 Freestar. After finding water in the computer housing, he suggested that we buy a rebuilt one (Ford does not supply PCM's for this van anymore) to see if that would solve the problems. However, the Ford dealership had to install the computer so that the programming could be completed. Otherwise, the original keys would not work. In summary, the PCM did solve the problems, until the next weather event. Then, the problems started all over again. We have now had the computer replaced, dried, and/or sealed several times, but water keeps getting inside. The local Ford dealership and other mechanics have been working diligently in an effort to seal the PCM. Recall and class action needed!

- Jasper, GA, USA

Engine stutters, won't run steady, idles over 2000rpm in neutral, continually dies, when engine dies steering hard(naturally), won't go in reverse, this problem causes numerous problems that are not safe when it does it on the road. The problem is apparently in moisture in the PCM. Torque converter was replaced in 2012. Has not done the problem for a year and did it again today( has not rained in more than a week) just going down the road and starts cutting out and dies! has done this many times since 2010. Ford knows about it! information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Broken Arrow, OK, USA

The contact owns a 2005 Ford Freestar. The contact stated that while driving 65 mph, the vehicle stalled without warning. The vehicle was taken to the dealer where the technician diagnosed that the torque converter needed to be replaced and that the vehicle was included in NHTSA campaign id number: 12V006000 (power train:automatic transmission:torque converter). The vehicle was repaired under the recall however, the repair failed to remedy the problem. The technician inspected the vehicle again and advised the contact that the transmission needed to be replaced. The manufacturer was made aware of the failure and did not offer any assistance since the vehicle was not included in any other recalls. The vehicle was not further repaired. The failure mileage was 90,000 and the current mileage was 118,000.

- S. Attleboro, MA, USA

This information is a collection of incidents that ultimately fit together. I have notice that the floor board of my van was wet. Since I have 3 kids I just shrugged it off. This past week I notice the floor mats weren't wet only the carpet beneath it was soaked. My kids don't spill just under the mats. The water must be entering from the outside in. The van was acting weird on and off -no check engine light until it started happen more frequently. June 2012, I got the P1340 code that the camshaft position sensor had gone bad, I replaced it, went out again, I was told it could have been a faulty part, changed it again, went out again, decided this is beyond me. I took it to the dealership and they "fixed" the camshaft position sensor and another part that was causing the camshaft position sensor not to work. ($900) it broke again because the part they put in was defective. They replaced the defective part and the check engine light came back on again. After they had the car for 2 weeks they found another small problem. ($130) I insisted at the time that they didn't make the proper repairs. They assured me that it all still needed to be done. (caught some double talk) I experienced a few more issues with the van losing power. (July, September, October -check engine light did not turn on.) I:N December the car turned off and I was only able to get about 25ft per restart and the light came on. I've noticed other features not working properly or working intermittently. (power locks, power windows, radio, power doors, key remote...) I have learned that other 2005 Freestar owners have experienced similar incidents caused by water leaking into the car through the windshield wiper blades and running down the wire harness causing multiple parts to short out from time to time. Please look into this. I have 3 children and no more money for "let's try this repairs".

- Yorktown, VA, USA

The contact owns a 2005 Ford Freestar. The contact stated that while driving 45 mph, the vehicle began to loose power without warning. The contact stated that the vehicle would decelerate rapidly and then was able to continue driving. The vehicle was not taken to the dealer for inspection. The vehicle was not repaired. The manufacturer was notified and stated that there were no recalls on the vehicle. The failure mileage was 85,000.

- Holbrook, NY, USA

This vehicle has a continuing problem with the PCM shorting out due to water entering the wiring harness through the windshield wipers. Once the PCM short circuits the transmission does not function causing the car to loose its' motion. This occurs without warning and places the occupants of the vehicle at greater risk of being involved in an accident as the car simple ceases to work. The company has currently recalled this make and model to replace a defective torque converter. Although this seems to solve the problem initially, the long term problem of water seeping into the PCM will cause the transmission to fail time and time again.

- Holbrook, NY, USA

Transmission seemed to be acting up trying to maintain highway cruising speeds, 55-65 mph. Kept shuttering and vibrating. Balise Ford in hyannis MA found a problem in the transmission. They had the vehicle for approximately 60 days time. During that time they removed the transmission under the direction of Ford esp extended warranty center approximately 8 times, replacing a new and different part each time they removed the transmission and reinstalled it. After the repair "attempt" exceeded the replaced value, Ford esp extended warranty program decided to replace the entire transmission with a Ford factory rebuilt transmission. After the transmission was replaced the vehicle started doing the same thing all over again. We then got a recall on the vehicle and inquired. Come to find out the torque converter was the problem and the rebuilt transmission from Ford factory had one of the bad converters and that needed to replaced as soon as parts were available. The new converter came in and was installed in the vehicle approximately August 2012. Late November 2012 the vehicle, now with 46,000 one owner pampered miles on it is doing the same thing. The vehicle shutters when floating in and out of gears when trying to maintain highway speeds, 55 - 65 mph. When this occurs you can feel the rumble in the vehicle and the tachometer needle jumps around. This vehicle is my mother's only means of transportation and she is a 72 year old woman who has had 2 total knees replacements. I purchased this vehicle brand new for her thinking it would be a dependable vehicle, and with her low amount of miles driven year, assumed it would last an easy 10 years. Not the case. I am afraid to have her use this vehicle and Ford needs to step up to the plate and fix it once and for all or replace the vehicle for us.

- Dennis, MA, USA

Received recall for torque converter- had it replaced on Aug 20, 2012. On Nov. 19th the van wouldn't go pass 20 mph. Drove slow approx. 3 miles to destination. Had it towed to dealership to check out problem at initial contact was told they knew of no problems relating to torque converter replacement. After checking van out was told that we needed a new transmission, at second contact was told they were aware of torque recall issues but nothing would be done for us. We had not had any problems with transmission prior to Nov 19th. When asked, was also told that they did not flush and replace fluids with the torque converter recall service as this extra cost was not part of the recall. We were told by an independent mechanic that if fluids were not changed that it could cause the transmission to fail which it did. Was quoted a high cost to replace transmission, ended up using disabled vehicle as a trade 'as is' to purchase a working vehicle. Other issues with vehicle prior to last incident were electrical functions not working, sliding doors would reopen upon closing, had to turn off auto doors, backup warning quit working, traction control button didn't work, dvd player would start running on its own.

- Amberg, WI, USA

I had a torque converter replaced 4 days ago on my van due to a recall and 4 days after repair my car shuts down in the middle of driving. Now the Ford dealer is telling me it has nothing to do with the torque converter which I find impossible since I haven't had any other issues before with my car just your basic brake repairs.

- Chicago, IL, USA

The contact owns a 2005 Ford Freestar. The contact stated that she received notification of NHTSA campaign id number: 12V006000 (power train:automatic transmission:torque converter) and attempted to have the vehicle repaired in June 2012. The dealer informed her that she had to order the recall part and that she should receive notification when the part became available. The contact received the letter and contacted the dealer who then stated that they did not have the part available and that she would have to be added to the waiting list. The vehicle was never repaired. The failure mileage was 135,000.

- Bayville, NJ, USA