2004 Ford Freestar Structure Problems

Source: NHTSA · Updated Jul 11, 2025 · 94 complaints analyzed

Owners have filed 94 complaints with NHTSA about structure problems on the 2004 Ford Freestar, 8% of all complaints for this model year. Half of the reports with a mileage happened before 114,000 miles. The words owners use most often: “wheel well” (35% of reports).

What owners describe

Phrases that appear unusually often in these complaints compared with complaints about other cars.

  • Wheel well: mentioned in 33 of 94 complaints (35%)
  • Row seat: mentioned in 27 of 94 complaints (29%)
  • Rear driver: mentioned in 10 of 94 complaints (11%)
  • Completely rusted: mentioned in 9 of 94 complaints (10%)

At what mileage do structure problems happen?

Based on 84 complaints that reported the odometer reading.

Under 10k miles3 · 4%
10k–25k miles2 · 2%
25k–50k miles2 · 2%
50k–75k miles9 · 11%
75k–100k miles21 · 25%
100k–150k miles30 · 36%
150k+ miles17 · 20%

How serious are the reports?

Of 94 complaints, 1 mention a crash, 1 a fire, 3 an injury.

Ford Freestar structure complaints by model year

Peak: 2004, with 94 complaints
2004: 942004942005: 332005332006: 5200652007: 420074

n = 136 complaints · Source: NHTSA

Model yearStructure complaintsShare of that yearMedian miles
2007 Freestar46%117,500
2006 Freestar51%97,994
2005 Freestar334%82,049
2004 Freestar948%114,000

When owners reported it

Peak: 2012, with 35 complaints
2004: 1200412005: 222008: 3200832009: 112010: 1201012011: 10102012: 352012352013: 17172014: 3201432015: 112016: 8201682017: 552018: 4201842019: 222020: 120201

n = 94 complaints · Source: NHTSA

Related recalls (0)

No safety recall lists structure for the 2004 Ford Freestar. A pattern of complaints does not always lead to a recall.

What owners report

Short excerpts of recent complaints, with personal details removed. Full reports are on NHTSA.gov.

The part that has the clip for back seat fell out and now there is a 5 by 5 inch hole going into the wheel well and the seat has nothing to clip onto and be secure, this was recalled in this model

Received Dec 3, 2020 · NHTSA complaint 11377831

Tl* the contact owns a 2004 ford freestar. The contact stated that both the driver and passenger side electric sliding doors would not close properly and would randomly open. The vehicle was not diagnosed or repaired. The local dealer (dick smith ford, 7201 garners ferry rd, columbia, sc) and the…

Received Jul 25, 2019 · NHTSA complaint 11234763

Tl* the contact owns a 2004 ford freestar. While the vehicle was undergoing routine maintenance by an independent mechanic, the contact was informed that the control arm was protruding through the frame and created a hole. In addition, the check engine indicator illuminated. The local dealer was…

Received Jun 17, 2019 · NHTSA complaint 11220567
Ford Freestar
2006 Ford Freestar photographed in USA.. Representative photo; appearance varies by model year. Photo: U.S. National Highway Traffic Safety Administration, Public domain, via Wikimedia Commons.

Frequently asked questions

Do all 2004 Ford Freestars have structure problems?

No. NHTSA has 94 owner complaints about structure for the 2004 Ford Freestar (8% of the 1,227 complaints for this model year). Complaint data shows that the problem is reported, not how many of all cars sold are affected.

Was there a recall on the 2004 Ford Freestar structure?

No recall currently lists structure for this vehicle.

At what mileage do structure problems start?

The median reported mileage is 114,000 miles: half of the reports with a mileage came before that.

What do owners say about structure problems on the 2004 Ford Freestar?

The most frequent phrase is “wheel well”, in 33 of 94 complaints, followed by “row seat” (27).

Other 2004 Ford Freestar problems

See all 2004 Ford Freestar problems or structure problems across all Freestar years.