Ford Freestar 2004-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Freestar Model Years: 2004, 2005, 2006, 2007 Codes Platform: Ford Front Drive Van (D272) 👋 Introduction Market Position Segment: Full-size Minivan Target Audience:...

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Art.-Nr: 584919

Stichworte: 2004 2005 2006 2007 Car Cars Ford Freestar

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Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

Freestar

Model Years:

2004, 2005, 2006, 2007

Codes

Platform:

Ford Front Drive Van (D272)

👋 Introduction

Market Position

Segment:

Full-size Minivan

Target Audience:

Families, individuals requiring versatile people and cargo transport.

Competitive Analysis

Key Competitors:

Dodge Grand Caravan/Chrysler Town & Country, Honda Odyssey, Toyota Sienna, Chevrolet Uplander/Buick Terraza/Pontiac Montana SV6.

Key Features

Powertrain Options:

Available V6 engines offering a balance of power and efficiency for its class.

Interior Flexibility:

Configurable seating arrangements for passenger and cargo versatility.

Ride Comfort:

Designed for a comfortable ride, especially for longer journeys.

Manual Utility:

Provides detailed, factory-authorized information essential for maintaining and repairing the Freestar.

📋 Manual Details

Coverage Areas

Engines Covered:

3.9L V6 (232ci) Essex, 4.2L V6 (256ci) Essex, 4.2L V6 (256ci) Essex (Flex Fuel)

Transmissions Covered:

4-speed Automatic (4F50N)

Drivetrain Covered:

Front-Wheel Drive (FWD)

Page Count

Estimated Pages:

Approximately 2000+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, and repair of all engine components, including timing, lubrication, cooling, fuel, and emission control systems.

Engine Performance:

Detailed troubleshooting and diagnosis for engine performance issues, including misfires, rough idling, power loss, and poor fuel economy.

Transmission:

Comprehensive coverage of the 4F50N automatic transmission, including removal, installation, overhaul, diagnosis, and fluid service.

Brakes:

Diagnosis, repair, and maintenance of the hydraulic and anti-lock braking system (ABS), including disc and drum components.

Suspension:

Detailed procedures for front and rear suspension systems, including struts, shocks, control arms, bushings, and alignment specifications.

Steering:

Diagnosis and repair of the power steering system, including pumps, hoses, steering rack, and linkages.

Electrical:

Extensive coverage of the vehicle's electrical system, including wiring diagrams, component locations, diagnosis of circuits, lighting, accessories, and charging systems.

HVAC:

Service and repair of the heating, ventilation, and air conditioning system, including refrigerant handling, component replacement, and diagnosis.

Body:

Procedures for body repair, panel replacement, door mechanisms, interior trim, and glass service.

Chassis:

Frame and chassis repair, including body-to-frame mounts and structural components.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, belt inspections, and tune-up procedures.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex vehicle issues, often using flowcharts and symptom-based guides.

Repair:

Detailed, step-by-step instructions for component removal, installation, and repair across all vehicle systems.

Diagnostics:

Advanced diagnostic techniques, including scan tool usage, circuit testing, and component testing procedures.

Specifications:

Torque specifications, clearances, fluid capacities, electrical testing parameters, and alignment data.

Technical Depth

Depth:

Comprehensive, covering everything from basic owner-performed maintenance to complete engine and transmission overhauls, including electrical diagnostics and body repairs.

📊 Manual Specifications

File Format

Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Viewability:

Viewable on computers, tablets, and smartphones.

Print Quality

Resolution:

High-resolution scans suitable for printing individual pages or sections.

Binding Type

Binding:

N/A (Digital Product)

Paper Type

Paper Type:

N/A (Digital Product)

⚙️ Engine Specifications

Primary Engine

Engine Code:

3.9L V6 (3F)

Displacement:

3949 cc (232 cubic inches)

Bore X Stroke:

93.5 mm x 90.2 mm (3.68 in x 3.55 in)

Compression Ratio:

9.0:1

Horsepower:

193 hp @ 4,500 RPM (approx.)

Torque:

245 lb-ft @ 3,250 RPM (approx.)

Valvetrain:

Overhead Valve (OHV), 2 valves per cylinder

Fuel System:

Electronic Fuel Injection (EFI)

Secondary Engine

Engine Code:

4.2L V6 (4.2L)

Displacement:

4172 cc (255 cubic inches)

Horsepower:

202 hp @ 4,000 RPM (approx.)

Torque:

260 lb-ft @ 3,000 RPM (approx.)

Fuel System

Fuel Type:

Unleaded gasoline / E85 Flex Fuel (4.2L option)

Fuel Pump Pressure:

Refer to manual for specific PSI

Performance

Engine Management System:

Ford EEC-V (or later variant)

🔧 Transmission

Standard

Type:

4-speed Automatic

Model Code:

4F50N

Gear Ratios:

Refer to manual for specific ratios (e.g., 2.71:1 First, 1.57:1 Second, 1.00:1 Third, 0.69:1 Fourth)

Fluid Type:

MERCON V Automatic Transmission Fluid (ATF)

Features

Shifting:

Electronically controlled, with overdrive.

Torque Converter Lockup:

Variable, controlled by PCM for improved efficiency.

📐 Dimensions

Exterior

Wheelbase:

123.7 inches (3142 mm)

Length:

200.2 inches (5085 mm)

Width:

77.4 inches (1966 mm)

Height:

68.5 inches (1740 mm)

Interior

Passenger Volume:

Approximately 150-160 cubic feet (varies by configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approximately 30-40 cubic feet (varies)

Cargo Volume Behind 2Nd Row:

Approximately 80-90 cubic feet (varies)

Weights

Curb Weight:

Approx. 4,300 - 4,600 lbs (1950 - 2087 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,800 - 6,000 lbs (2630 - 2721 kg)

Wheels Tires

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inch)

Standard Tire Size:

P225/60R16

Optional Tire Size:

P235/55R17 (on some trims)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Crash Test:

5-Star (for most model years and configurations, check specific year reports)

NHTSA Frontal Passenger Crash Test:

5-Star (for most model years and configurations, check specific year reports)

NHTSA Side Driver Crash Test:

4-Star (for most model years and configurations, check specific year reports)

NHTSA Side Rear Passenger Crash Test:

4-Star (for most model years and configurations, check specific year reports)

IIHS Frontal Offset Crash Test:

Good (for most model years, check specific year reports)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Electronic Stability Control:

Optional Electronic Stability Control (AdvanceTrac)

Passive Features

Airbags Front:

Driver and front-passenger airbags

Airbags Side Curtain:

Optional side-curtain airbags for all rows

Seatbelts:

Three-point seatbelts for all seating positions, height-adjustable front belts.

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, optional premium audio, rear-seat entertainment system.

Navigation:

Optional factory navigation system available on higher trims.

Driver Assistance

Parking Sensors:

Optional rear parking assist system.

Cruise Control:

Standard cruise control.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack.

Power Outlets:

Multiple 12V power outlets.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, or every 7,500 miles (12,000 km) / 12 months with synthetic oil (refer to manual for precise recommendation based on usage).

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.

Spark Plug Replacement:

3.9L V6: Approx. 100,000 miles (160,000 km) using long-life plugs; 4.2L V6: Approx. 100,000 miles (160,000 km) using long-life plugs (refer to specific plug type).

Transmission Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), or under severe usage conditions. Filter replacement recommended during fluid service.

Fluid Specifications

Engine Oil:

SAE 5W-30 API SG, SH, SJ or ILSAC GF-2 certified (check manual for exact Ford specification).

Coolant:

Ford Premium Engine Coolant (Green)

Brake Fluid:

DOT 3

Power Steering Fluid:

Ford Power Steering Fluid (or Mercon V ATF)

Known Issues

Transmission Reliability:

Some reports of issues with the 4F50N transmission, particularly concerning solenoid pack failures or torque converter clutch issues.

Engine Mounts:

Premature wear or failure of engine mounts can lead to excessive vibration.

Rear Wheel Bearings:

Potential for premature rear wheel bearing failure, especially on earlier models.

Door Latches And Handles:

Issues with interior and exterior door latches and handles can occur.

HVAC Blend Door Actuators:

Common failure of HVAC blend door actuators can result in improper air temperature control.

📚 Vehicle History

Brand Heritage

Ford Minivan Legacy:

The Freestar is part of Ford's long history in the minivan segment, succeeding the Windstar.

Model Evolution

Predecessor:

Ford Windstar (1995-2003)

Debut:

Introduced for the 2004 model year, representing a significant redesign over the Windstar.

Updates:

Minor styling updates and feature additions throughout its production run, including available all-wheel-drive in early models (though primarily FWD).

Production

Manufacturing Plant:

Oakville Assembly Plant, Oakville, Ontario, Canada

Production Years:

2003-2007 (for model years 2004-2007)

🏆 Awards & Recognition

Recognitions

Safety Awards:

Achieved 5-star frontal crash test ratings from NHTSA in many configurations, indicating good occupant protection.

Ratings

IIHS Ratings:

Generally rated 'Good' in IIHS frontal offset tests, a positive indicator for structural integrity.