Ford Freestar Structure Problems

Source: NHTSA · Updated Jun 7, 2026 · 136 complaints analyzed

Owners have filed 136 complaints with NHTSA about structure problems on the Ford Freestar across 4 model years. The 2004 model year has the most (94). The words owners use most often: “wheel well” (27% of reports).

What owners describe

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

  • Wheel well: mentioned in 37 of 136 complaints (27%)
  • Row seat: mentioned in 30 of 136 complaints (22%)
  • Rear driver: mentioned in 12 of 136 complaints (9%)
  • Completely rusted: mentioned in 10 of 136 complaints (7%)

At what mileage do structure problems happen?

Based on 121 complaints that reported the odometer reading.

Under 10k miles5 · 4%
10k–25k miles3 · 2%
25k–50k miles4 · 3%
50k–75k miles17 · 14%
75k–100k miles28 · 23%
100k–150k miles44 · 36%
150k+ miles20 · 17%

How serious are the reports?

Of 136 complaints, 1 mention a crash, 2 a fire, 10 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 41 complaints
2004: 1200412005: 332007: 1200712008: 772009: 4200942010: 442011: 122011122012: 41412013: 212013212014: 882015: 2201522016: 992017: 102017102018: 552019: 3201932020: 442023: 120231

n = 136 complaints · Source: NHTSA

Related recalls (1)

Structure:body:hatchback/liftgateMar 9, 2006 · NHTSA campaign 06V069000 · 12,728 vehicles

Model years: 2005, 2006

Problem: On certain vans equipped with the power liftgate option, the power liftgate motor automatically disengages after the liftgate is powered open.

Risk: In the event of a liftgate strut malfunction, the liftgate can fall freely with no prior warning. Anyone standing beneath the liftgate may be injured if the liftgate falls.

Fix: Dealers will reprogram the power liftgate module to reduce the likelihood that the liftgate could fall free of charge. The recall began on march 15, 2006. Owners may contact ford at 1-800-392-3673.

What owners report

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

The rear wheel well has rusted on both sides and completely rusted out a large hole (approx. 1 ft diameter area visibly effected) in the the body of the van. The rusted out section is where the back seat is anchored to the frame, so the rust has cause the seat to no longer be securely anchored to…

Received Mar 10, 2023 · NHTSA complaint 11511200

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

I purchased a 2006 ford freestar van on 10-13-2020 and 10-16-2020 car lights started blinking on and off in an outside the van. Started to drive home the van started jerking bad and smoking. Cut off in the middle of the road while my children an pregnant daughter in law were in the van. The axle…

Received Oct 18, 2020 · NHTSA complaint 11364877

I wrote on this yesterday but did some more research on this vehicle. There have been numerous recalls on these type of vehicles. Recall #12v006000 on the torque converter output shaft. Recall began august 9 2012. This is a serious matter i just recently purchased this vehicle to take my 8…

Received May 13, 2020 · NHTSA complaint 11324406

While you are driving the vehicle. The vehicle has something wrong with the transmission. I looked up ford recalls and it states that this type of vehicle has been recalled for transmission problems. Torque something thing. The van has only 141000 miles and is rusted severely underneath it. Very…

Received May 12, 2020 · NHTSA complaint 11324345
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 Ford Freestars have structure problems?

No. NHTSA has 136 owner complaints about structure for the Ford Freestar. Complaint data shows that the problem is reported, not how many of all cars sold are affected.

Was there a recall on the Ford Freestar structure?

Yes: 1 safety recall list structure. Check your VIN on NHTSA.gov to see whether the fix was done on your car.

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

The most frequent phrase is “wheel well”, in 37 of 136 complaints, followed by “row seat” (30).

Other Ford Freestar problems

See all Ford Freestar problems.