IllustrationREAR 3RD ROW SEAT LATCH IS COMPLETELY RUSTED THROUGH MAKING THE REAR SEAT COMPLETELY UNSAFE AND UNUSABLE. COULD CAUSE SERIOUS INJURIES IN A ACCIDENT IF RUST GOES UNDETECTED, VEHICLE IS KEPT IN GARAGES AND WELL MAINTAINED. *TR UPDATED 05/31/12*LJ
2004 Ford Freestar
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Freestar years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
470–25K
10025–50K
23250–75K
32175–100K
280100–150K
111150K+
1,091 reports with mileage · 136 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Power Train. Review the 851 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 118 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Structure. Review the 94 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
16 crash reports14 fire reports17 injury reports
Structure complaints
94 reports1) WE NOW HAVE TRANSMISSION FAILURE. THE COST TO REPAIR EQUALS MOST OF THE VEHICLE'S VALUE. 2) DRIVER-SIDE PASSENGER DOOR CLOSES AND OPENS AGAIN CONTINUALLY. WE GET OUT AND DO THAT MANUALLY. 3) WITH FOOT OFF ACCELERATOR, GOING DOWN HILLS, THE FREESTAR TRANSMISSION HAS "CHUGGED" FOR A COUPLE OF YEARS NOW, REPRODUCE-ABLE A…
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1) WE NOW HAVE TRANSMISSION FAILURE. THE COST TO REPAIR EQUALS MOST OF THE VEHICLE'S VALUE. 2) DRIVER-SIDE PASSENGER DOOR CLOSES AND OPENS AGAIN CONTINUALLY. WE GET OUT AND DO THAT MANUALLY. 3) WITH FOOT OFF ACCELERATOR, GOING DOWN HILLS, THE FREESTAR TRANSMISSION HAS "CHUGGED" FOR A COUPLE OF YEARS NOW, REPRODUCE-ABLE AT DEALER LAST YEAR BUT THEY COULD NOT FIND CAUSE (WE RAN OUT OF MONEY LETTING THEM STUDY IT).... WE NOW KNOW THESE THINGS ARE ALL RELATED. RESEARCH ONLINE SHOWS OTHER OWNERS HAVE FOUND WET PCM TO BE PROMULGATING CAUSE FOR DOOR SENSORS AND THE CAUSE FOR PREMATURE FAILURE OF TRANSMISSION DUE TO DAMAGE CAUSED BY PCM OVER TIME. TO PUT PCM BELOW WINDSHIELD, WITHOUT PROPER WATERPROOF HOUSING, THIS IS A DESIGN ERROR THAT CAUSES VERY, VERY EXPENSIVE DAMAGE AND REPAIRS THAT WILL BE REQUIRED AGAIN, WITHOUT PCM BEING TOUCHED. DEALERS REPAIR DAMAGE (NOT CAUSE) UNDER WARRANTY, BUT MOST OF US ARE NOW OUT OF WARRANTY. WE'VE ONLY GOT 74000 VERY WELL-CARED FOR MILES. PROBLEM IS THE VEHICLE IS NOW NOT DRIVABLE; TRANSMISSION IS SHOT. FORD REFUSES TO MAKE GOOD FOR US. THE SCHEDULE RECALL FOR THE TRANS AXLE WILL BE OUR NEXT REPAIR, BUT IT WON'T REPLACE THE TRANSMISSION! SEE: HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F0FB94A!MAKE=FORD&MODEL=FREESTAR&ED_MAKEINDEX=.F0FB94A. *TR
LEFT REAR SEAT NO LONGER LATCHES MAKING IT UNSAFE. THE SEAT NO LONGER LATCHES BECAUSE LATCH THAT WAS FASTENED TO THE LEFT REAR WHEEL WELL HAS RUSTED COMPLETELY OFF THE WHEEL WELL. *TR
NOTICED INSIDE CARPET WAS WET ON THE REAR LEFT SIDE, REMOVED THE INSIDE REAR WHEEL PANEL AND FOUND THE THIRD ROW SEAT LATCH HAD COMPLETELY RUSTED THROUGH TO THE OUTSIDE OF THE CAR ALLOWING WATER TO ENTER THE CAB SPACE AND NOW THE THIRD ROW SEAT IS UNSAFE DUE TO THE SEAT NOT BEING ABLE TO LATCH. *TR
WHEN MAKING A RIGHT TURN WITH A FULL LOAD (MY WIFE, 2 KIDS, MY PARENTS AND I) A VIBRATION OCCURRED IN THE LEFT REAR WHEEL WELL. I COULDN'T FIND THE PROBLEM MYSELF SO I TOOK THE VAN TO THE FORD DEALER THE NEXT DAY AND THEY DIAGNOSED THAT THERE WAS RUSTING IN THE LEFT REAR WHEEL WELL WHICH CAUSED FRICTION AGAINST THE TIRE WHEN TU…
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WHEN MAKING A RIGHT TURN WITH A FULL LOAD (MY WIFE, 2 KIDS, MY PARENTS AND I) A VIBRATION OCCURRED IN THE LEFT REAR WHEEL WELL. I COULDN'T FIND THE PROBLEM MYSELF SO I TOOK THE VAN TO THE FORD DEALER THE NEXT DAY AND THEY DIAGNOSED THAT THERE WAS RUSTING IN THE LEFT REAR WHEEL WELL WHICH CAUSED FRICTION AGAINST THE TIRE WHEN TURNING RIGHT WITH A FULL LOAD. THE SERVICE MANAGER AT THE FORD DEALER RECOMMENDED THAT I DO NOT DRIVE THE VEHICLE AND REPLACE THE VEHICLE AS IT WAS TOO DANGEROUS TO DRIVE. I WAS NOT PLANNING TO SELL THE VAN FOR SCRAP AFTER 5.5 YEARS AND I COULDN'T MORALLY SELL A CAR THAT I WOULDN'T FEEL SAFE DRIVING WITH MY OWN FAMILY. I TOOK THE VAN TO A BODY SHOP AND THEY RECOMMENDED A SPECIALTY SHOP. THE SPECIALTY SHOP IDENTIFIED THE PROBLEM AS A PANEL THAT WAS NOT SEALED WELL WHICH CAUSED PREMATURE RUSTING. THEY WERE ABLE TO CUT OUT THE AREA AND REPLACE THAT PART OF THE WHEEL WELL. I SEE THIS AS A VERY SERIOUS SAFETY HAZARD THAT I HOPE OTHERS DON'T ENCOUNTER. IF I HAD NOT TAKEN CARE OF THIS PROBLEM IMMEDIATELY THE TIRE COULD HAVE BEEN DAMAGED WHILE TURNING RIGHT WITH A FULL LOAD AND CAUSED A SERIOUS ROLLOVER ACCIDENT. I WAS NOT HAPPY WITH THE FORD SERVICE MANAGER'S ADVICE OF BUYING A NEW CAR VERSUS HELPING ME FIX THE PROBLEM. I FELT IT WAS IMPORTANT TO FILE A SAFETY COMPLAINT AS THE RESULT OF THIS TYPE OF PREMATURE WEAR ON A VEHICLE COULD TURN OUT TO BE TRAGIC FOR SOMEONE. *KB
TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE VEHICLE WOULD STALL WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER AND A COVER WAS PLACED OVER THE COMPUTER TO KEEP WATER FROM GETTING ENTERING AND DAMAGING THE COMPUTER BUT THE REPAIR DID NOT CORRECT THE FAILURE. THE VEHICLE WAS TAKEN BACK TO THE DEAL…
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TL* THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE VEHICLE WOULD STALL WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER AND A COVER WAS PLACED OVER THE COMPUTER TO KEEP WATER FROM GETTING ENTERING AND DAMAGING THE COMPUTER BUT THE REPAIR DID NOT CORRECT THE FAILURE. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHERE THE DEALER ADDED SEALANT TO THE COVER THAT WAS PROTECTING THE COMPUTER. THE VIN WAS NOT AVAILABLE. THE CURRENT MILEAGE WAS 103,000 AND THE FAILURE MILEAGE WAS UNKNOWN. UPDATED 03/27/12*LJ THE CONSUMER STATED THE COMPUTER IS LOCATED DIRECTLY UNDER THE WINDSHIELD, ALLOWING WATER TO DRIP ON THE COMPUTER.
TL - THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE HOOK THAT HELD THE REAR DRIVER SIDE CONVERTIBLE BENCH SEAT IN PLACE WAS COMPLETELY CORRODED. THE CONTACT MENTIONED THAT THE DAMAGE WAS SO SEVERE THAT IT RUSTED THROUGH THE BODY OF THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MAD…
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TL - THE CONTACT OWNS A 2004 FORD FREESTAR. THE CONTACT STATED THAT THE HOOK THAT HELD THE REAR DRIVER SIDE CONVERTIBLE BENCH SEAT IN PLACE WAS COMPLETELY CORRODED. THE CONTACT MENTIONED THAT THE DAMAGE WAS SO SEVERE THAT IT RUSTED THROUGH THE BODY OF THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 137,000. KMJ
PAINT PEELING OFF ROOF AND HOOD ,LOOKS LIKE THEY USED TWO DIFFERENT PRIMERS. *TR
UPON OPENING THE FOLDING THIRD ROW SEAT, THE BOTTOM LATCH FAILED TO ENGAGE WITH THE SEAT. FURTHER INSPECTION SHOWED THAT THE ENTIRE LATCH PANEL HAD RUSTED AWAY FROM THE BODY OF THE CAR AND WAS SITTING IN THE WHEEL WELL. THERE IS NOW A HOLE IN THE SIDE OF THE VAN AND THE THIRD ROW SEAT IS UNUSABLE. AT 7 YEARS OLD, THIS LEVEL OF …
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UPON OPENING THE FOLDING THIRD ROW SEAT, THE BOTTOM LATCH FAILED TO ENGAGE WITH THE SEAT. FURTHER INSPECTION SHOWED THAT THE ENTIRE LATCH PANEL HAD RUSTED AWAY FROM THE BODY OF THE CAR AND WAS SITTING IN THE WHEEL WELL. THERE IS NOW A HOLE IN THE SIDE OF THE VAN AND THE THIRD ROW SEAT IS UNUSABLE. AT 7 YEARS OLD, THIS LEVEL OF RUST IS VERY PREMATURE. *TR
TL* THE CONTACT OWNS A 2004 FORD FREESTAR. WHILE THE VEHICLE WAS PARKED THE CONTACT LOWERED THE THIRD ROW SEATING TO THE FLOOR WHEN HE NOTICED THE SAFETY LATCH ATTACHED TO THE REAR WHEEL WELLS WAS CORRODED FROM THE INSIDE OUT AND WERE FRACTURED. THE CONTACT STATED THE THIRD ROW SEAT COULD NOT BE USED BECAUSE IT WOULD BE UNSAFE I…
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TL* THE CONTACT OWNS A 2004 FORD FREESTAR. WHILE THE VEHICLE WAS PARKED THE CONTACT LOWERED THE THIRD ROW SEATING TO THE FLOOR WHEN HE NOTICED THE SAFETY LATCH ATTACHED TO THE REAR WHEEL WELLS WAS CORRODED FROM THE INSIDE OUT AND WERE FRACTURED. THE CONTACT STATED THE THIRD ROW SEAT COULD NOT BE USED BECAUSE IT WOULD BE UNSAFE IN THE EVENT OF A REAR END COLLISION. THE DEALER WAS MADE AWARE OF THE FAILURE AND REFUSED TO INSPECT THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 92,300. UPDATED 12/20/11*LJ UPDATED 01/19/12
Official recalls
413V081000 · Seats
Mar 7, 2013
Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
Consequence & remedy
Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
12V006000 · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
Jan 9, 2012
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence & remedy
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Additional source detail variants (2)
Power Train:automatic Transmission:torque Converter
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
Power Train:automatic Transmission
FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL.
Consequence: THIS CONDITION RESULTS IN A SUDDEN LOSS OF MOTIVE POWER WITH NO WARNING, INCREASING THE RISK OF A CRASH.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
04V446000 · Wheels:hub
Sep 13, 2004
CERTAIN MINIVANS MAY HAVE BEEN PRODUCED WITH FRONT WHEEL HUB ASSEMBLIES THAT WERE NOT HEAT TREATED CORRECTLY. THIS CONDITION MAY LEAD TO THE DEVELOPMENT OF SMALL CRACKS IN THE HUB.
Consequence & remedy
Consequence: IF THE CRACKS WERE TO PROGRESS, THIS COULD EVENTUALLY RESULT IN WHEEL SEPARATION. WHEEL SEPARATION MAY LEAD TO LOSS OF VEHICLE CONTROL, AND POTENTIALLY RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL REPLACE THE FRONT HUB, ROTORS, AND WHEEL BEARINGS. THE RECALL BEGAN SEPTEMBER 20, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
03V457000 · Steering:hydraulic Power Assist:hose, Piping, And Connections
Nov 6, 2003
ON CERTAIN MINIVANS, THE POWER STEERING LOW-PRESSURE LINE MAY NOT BE FULLY SEATED AT THE RACK AND PINION STEERING GEAR.
Consequence & remedy
Consequence: IF THIS LINE BECOMES DISCONNECTED, IT MAY CREATE THE POTENTIAL FOR FLUID TO COME INTO CONTACT WITH THE EXHAUST SYSTEM, WHICH COULD RESULT IN SMOKE OR FIRE.
Remedy: DEALERS WILL INSPECT THE POWER STEERING LOW-PRESSURE LINE TO ENSURE THAT IT IS SEATED PROPERLY AT THE RACK AND PINION STEERING GEAR. OWNER NOTIFICATION BEGAN NOVEMBER 10, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
8EQ12010 · Stabilus Rear Liftgate Struts Failing
Opened Sep 28, 2012 · Closed Dec 31, 2012
Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate:support Device/strut
Please see the attached closing resume summary.It has been attached to this document as a PDF.
EA12003 · Corrosion Of Third-Row Seat Attachment
Opened Apr 23, 2012 · Closed May 2, 2013
Status: closed (inferred from source dates) · Seats; Seats:mid/rear Assembly; Structure; Structure:body
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.
Additional source detail variants (4)
Seats
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.
Seats:mid/rear Assembly
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.
Structure:body
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.
Structure
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.
PE11039 · Corrosion Of Third-Row Seat Attachment
Opened Dec 21, 2011 · Closed Apr 27, 2012
Status: closed (inferred from source dates) · Latches/locks/linkages; Seats; Seats:mid/rear Assembly; Structure; Structure:body
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Additional source detail variants (5)
Latches/locks/linkages
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Seats
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Seats:mid/rear Assembly
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Structure:body
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
Structure
ODI has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.Additionally, ODI identified 4 similar reports from Ford's response to the investigation.Ford submitted a total of 10 reports to ODI (6 of 10 Ford reports are duplicates of ODI reports).The complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).The first report of this condition was received in March 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.ODI seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.In addition to the subject vehicles, ODI also will collect and review information on MY 2005-2007 Freestar/Monterey vehicles that appear to have a seat design identical to the subject vehicles.To date, ODI is not aware of any similar complaints on the MY 2005-2007 vehicles.ODI also will collect and review information on Freestar/Monterey vehicles used outside of the salt belt states.This Preliminary Evaluation has been upgraded to an Engineering Analysis (EA12-003) to further assess whether a safety defect exists in the subject vehicles.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
PE11033 · Service Jack Failure
Opened Sep 13, 2011 · Closed Dec 7, 2012
Status: closed (inferred from source dates) · Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
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
PE10033 · Engine Stalling
Opened Aug 23, 2010 · Closed Jul 15, 2011
Status: closed (inferred from source dates) · Power Train:automatic Transmission:control Module (tcm/pcm/tecm); Vehicle Speed Control
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.
Additional source detail variants (2)
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
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.
Vehicle Speed Control
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.
EA09016 · Transmission Torque Converter Failure
Opened Nov 10, 2009 · Closed Feb 2, 2012
Status: closed (inferred from source dates) · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
Additional source detail variants (2)
Power Train:automatic Transmission
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
Power Train:automatic Transmission:torque Converter
On January 4, 2012 Ford Motor Company submitted a Defect Information Report (NHTSA Recall No. 12V-006) to NHTSA regarding a defect in the performance of the transmission torque converter for approximately 205,896 Ford Freestar and Mercury Monterey vehicles.The supplier of the torque converter manufactured converters containing a pump shaft spline that did not consistently meet the specified heat treatment requirements.In normal use, the spline may wear excessively and eventually fails without warning.If a torque converter malfunctions due to a sheared pump drive spline, the vehicle will abruptly lose motive power.This problem affected model year 2004 and 2005 Freestar and Monterey minivans.During the investigation NHTSA identified 532 complaints alleging incidents of vehicle stall while driving due to torque converter failure.These failures were sudden and without any prior warning.Of the 490 complaints that reported the speed at the time of the failure:218 (44%) occurred at or above 55 mph; and 344 (70%) occurred at or above 40 mph.Of the 382 complaints that reported the position of the vehicle relative to traffic after it came to a stop following the loss of motive power: 122 (32%) alleged that the vehicle came to a stop in the flow of traffic and remained in the flow of traffic until pushed or towed out of the way; 225 (59%) reported that the vehicle was maneuvered to the side of the roadway and remained there until towed; and 35 (9%) reported that they were able to maneuver to a location away from the flow of traffic, such as a parking lot.Two crashes were allegedly caused by torque converter failure, including an incident in which a Freestar suddenly lost power in 65 mph traffic in an area where there was no shoulder available.As a result, the Freestar stopped in a travel lane and when trailing traffic maneuvered to avoid the stalled vehicle, a four vehicle collision occurred.In these types of circumstances NHTSA believes the defect presents an unreasonable risk to motor vehicle safety and so advised Ford.In its Defect Information Report, Ford refers to its response to NHTSA's Preliminary Evaluation information request, which stated that a vehicle that loses motive power due to torque converter malfunction remains readily controllable; the vehicle will coast during which it can be safely maneuvered and stopped because the engine continues to run.Because the engine continues to run, steering and braking are unaffected, and the vehicle's electrical system and directional signals remain functional.In view of the foregoing, NHTSA does not agree with this statement.This investigation is closed based on Ford's recall.
PE09033 · Torque Converter Output Shaft Failure
Opened Jul 15, 2009 · Closed Nov 17, 2009
Status: closed (inferred from source dates) · Power Train:automatic Transmission; Power Train:automatic Transmission:torque Converter
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.
Additional source detail variants (2)
Power Train:automatic Transmission
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.
Power Train:automatic Transmission:torque Converter
ODI HAS RECEIVED 227 OWNER COMPLAINTS ALLEGING A SUDDEN AND UNEXPECTED LOSS OF MOTIVE POWER DUE TO AN INTERNAL TRANSMISSION FAILURE IN THE SUBJECT VEHICLES.OF THOSE COMPLAINTS, 124 CAN BE ATTRIBUTED TO THE TORQUE CONVERTER OUTPUT SHAFT SPLINES STRIPPING CAUSING A SUDDEN LOSS OF POWER TO THE DRIVETRAIN.THE REMAINING 103 COMPLAINTS EXPERIENCED A LOSS OF MOTIVE POWER BUT THE SPECIFIC INTERNAL FAILURE CAUSE WITHIN THE TRANSMISSION IS NOT KNOWN.ODI HAS UPGRADED THE INVESTIGATION TO AN ENGINEERING ANALYSIS (EA09-016) TO CONTINUE ITS ASSESSMENT OF THE SCOPE, FREQUENCY AND SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.
DP09004 · Engine Stalling
Opened Jun 4, 2009 · Closed Sep 7, 2010
Status: closed (inferred from source dates) · Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
On May 6, 2009, NHTSA received a request for a hearing through Title 49 of the United States Code, Chapter 301, Motor Vehicle Safety, Part 557. the request was in reference to vehicle owner complaint, 10266067, filed with NHTSA on April 20, 2009, which described a problem with engine stall in a model year (MY) 2004 Ford Freestar minivan due to water entering the PCM.Part 557 of Title 49 of the Code of Federal Regulations establishes procedures for holding a hearing to determine whether a manufacturer has reasonably met its obligation to notify owners of a safety related defect.Because a safety related defect has not been determined regarding the alleged defect in MY 2004 Ford Freestar vehicles, the Office of Defects Investigation interpreted the request as a defect petition under Part 552 of Title 49 of the Code of Federal Regulations.In response to the Information Request letter sent by ODI for DP09-004, Ford indicated that a variety of symptoms could result from water intrusion into the PCM, including no start, rough idle, engine misfire, transmission performance degradation, lack of transmission engagement, illumination of the check engine light, and engine stall while driving or parked.Ford stated that it believes that the overall complaint rate for engine stalling is low and comparable to other similar stalling related investigations that the agency has recently closed.Ford stated that the water entry into the PCM is a customer satisfaction issue.ODI has granted DP09-004 and opened a Preliminary Evaluation, PE10-033, to further assess the scope, frequency and potential safety-related consequences of the alleged defect.