🏷️ Basic Information

Make:

Ford

Model:

Freestar

Model Years Covered:

2004, 2005, 2006, 2007

Generation Designation:

Second Generation (UA/UB)

Platform:

Ford D3 platform

👋 Introduction

Vehicle Segment:

Minivan

Target Audience:

Families seeking comfortable, versatile, and spacious transportation

Key Competitors:

Honda Odyssey, Toyota Sienna, Chrysler Pacifica/Voyager, Kia Sedona, Hyundai Entourage

Design Philosophy:

Modernized styling (compared to previous Windstar), increased interior volume, improved safety features

Powertrain Emphasis:

Focus on V6 engine performance and smoothness

Interior Flexibility:

Versatile seating arrangements, ample cargo space

📋 Manual Details

Primary Coverage:

Comprehensive mechanical and electrical repair, maintenance, and troubleshooting

Body And Chassis:

Body panels, structural components, interior trim, suspension, steering, wheels, tires

Powertrain:

Engine, transmission, drivetrain, exhaust system, fuel system

Electrical Systems:

Battery, charging system, ignition system, lighting, instrumentation, comfort/convenience controls, entertainment system, power accessories, body control module (BCM)

Brakes:

Hydraulic system, ABS, EBD, parking brake

HVAC:

Heating, ventilation, air conditioning systems

Troubleshooting:

Diagnostic procedures, common faults, fault code interpretation

Estimated Pages:

Over 1500 pages (typical for comprehensive factory service manuals)

Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain Systems:

Engine mechanical (including timing, valve train, lubrication, cooling), fuel injection, ignition, emission controls, exhaust, torque converter, automatic transmission (e.g., AX4N/AX4S), final drive, half-shafts

Chassis Systems:

Front and rear suspension (independent front, multi-link rear), power steering, braking system (including ABS), wheel hub assemblies

Body And Interior:

Body structural analysis, exterior panels, doors, hood, liftgate, glass, seals, interior trim panels, seats, airbags, restraints

Electrical And Electronics:

Wiring diagrams, component locations, diagnostic connectors, Body Control Module (BCM), Powertrain Control Module (PCM), Integrated Wheel Speed Sensor (IWSS), anti-theft, lighting (interior and exterior), power windows, power locks, remote keyless entry, horn, wipers/washers, infotainment system, climate control module

Maintenance Procedures:

Oil change, filter replacement, fluid level checks and top-offs, tire rotation, brake pad replacement, spark plug replacement, air filter replacement, coolant flush, battery testing and replacement

Repair Procedures:

Engine component overhaul (e.g., cylinder head, pistons), transmission diagnosis and repair, suspension component replacement, steering system repair, brake system bleeding and component replacement, electrical component diagnosis and replacement, interior component repair, exterior panel repair/replacement

Diagnostic Procedures:

Systematic troubleshooting charts, symptom-based diagnostics, use of scan tools (OBD-II), electrical circuit testing, mechanical component testing

Special Tools And Jigs:

Identification and usage instructions for specialized tools required for specific repairs or adjustments

Depth Of Information:

Factory-level detail, suitable for professional technicians and experienced DIY mechanics. Includes specifications, tolerances, diagnostic procedures, and repair sequences.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick information retrieval

Resolution:

High-resolution images, diagrams, and schematics for clarity

Layout:

Organized into logical sections with clear headings and index

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code 2004-2005:

SOHC Vulcan 3.9L V6 (VIN X)

Engine Code 2005-2007:

SOHC Duratec 3.9L V6 (VIN 3) - replacing Vulcan

Engine Code 2007:

SOHC Duratec 4.2L V6 (VIN 3) - replacement for 3.9L Duratec

Horsepower 3.9L Vulcan:

193 hp @ 4,500 rpm

Torque 3.9L Vulcan:

240 lb-ft @ 3,500 rpm

Horsepower 3.9L Duratec:

207 hp @ 4,800 rpm

Torque 3.9L Duratec:

249 lb-ft @ 3,500 rpm

Horsepower 4.2L Duratec:

215 hp @ 4,800 rpm

Torque 4.2L Duratec:

253 lb-ft @ 3,500 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

18.0 gallons (approx.)

🔧 Transmission

Transmission Type:

4-speed Automatic Overdrive

Transmission Codes:

AX4N, AX4S (depending on engine and year)

Optional Transmission:

None (All were automatic)

Transmission Features:

Electronic shift control, overdrive gear for fuel efficiency

Transmission Fluid Type:

MERCON V Automatic Transmission Fluid (ATF)

📐 Dimensions

Length:

200.2 - 201.1 inches

Width:

76.4 inches

Height:

68.4 - 68.5 inches

Wheelbase:

121.5 inches

Passenger Volume:

156.4 cubic feet (approx.)

Cargo Volume Behind 3Rd Row:

26.3 cubic feet (approx.)

Cargo Volume Behind 2Nd Row:

88.2 cubic feet (approx.)

Cargo Volume Behind 1St Row:

141.1 cubic feet (approx.)

Curb Weight:

4,300 - 4,600 lbs (approx.)

Gross Vehicle Weight Rating Gvw:

5,740 - 6,000 lbs (approx.)

🛡️ Safety Features

NHTSA Rollover Rating:

4 out of 5 stars (for FWD models)

IIHS Crash Test Ratings:

Varied by year and test; frontal impacts generally rated 'Good' or 'Acceptable'

ABS:

Standard Anti-lock Braking System (ABS)

Ebd:

Electronic Brake-force Distribution (EBD)

Traction Control:

Available on some models

Airbags:

Frontal airbags, available side-impact airbags

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

Seatbelts:

Three-point seatbelts for all seating positions

💡 Technology Features

Audio Systems:

Available AM/FM stereo with CD player, optional premium audio systems, rear-seat entertainment options (DVD player).

Navigation:

Optional factory navigation system available on higher trim levels.

Rear Parking Aid:

Available rear parking sensors on select models.

Remote Keyless Entry:

Standard or optional, depending on trim level.

Power Sliding Doors:

Available on many models for convenience.

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 7,500 miles or 6 months (whichever comes first), depending on driving conditions and oil type used. Consult manual for specific recommendations based on oil viscosity and synthetic vs. conventional.

Air Filter Replacement Interval:

Every 30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement Interval:

Every 15,000 - 30,000 miles or annually, depending on environment.

Spark Plug Replacement Interval Vulcan:

Approx. 100,000 miles (Platinum or Iridium)

Spark Plug Replacement Interval Duratec:

Approx. 100,000 miles (Iridium)

Transmission Fluid Change Interval:

Every 50,000 - 100,000 miles, depending on usage. Frequent towing or severe use requires more frequent changes.

Coolant Flush Interval:

Every 50,000 - 100,000 miles or 5 years, whichever comes first.

Engine Oil Viscosity:

SAE 5W-20 (preferred for fuel economy and performance), SAE 5W-30 acceptable.

Engine Oil Specification:

API Service SN or SP, ILSAC GF-5 or GF-6

Engine Coolant Type:

Ford Gold Coolant (or equivalent HOAT - Hybrid Organic Acid Technology)

Brake Fluid Type:

DOT 3

Powertrain Issues:

Some reports of transmission solenoid issues, potential for intake manifold gasket leaks on certain Duratec engines, oil pan gasket leaks.

Suspension Issues:

Premature wear of ball joints and tie rod ends in some cases, especially with higher mileage vehicles.

Electrical Issues:

Intermittent issues with power sliding doors, dashboard warning lights, and power accessory failures have been reported.

HVAC Issues:

Blend door actuator failures leading to improper temperature control are a known concern.

Brake Issues:

Rotor warping and premature brake pad wear can occur.

📚 Vehicle History

Ford Minivan History:

Ford has a long history in the minivan segment, notably with the Aerostar and Windstar models.

Freestar Predecessor:

Replaced the Ford Windstar

Platform Sharing:

Shared the Ford D3 platform with other Ford/Mercury products like the Five Hundred, Freestyle, and Monterey.

Facelift Updates:

Received minor styling updates and powertrain revisions during its production run.

Production Years:

2004-2007

Manufacturing Location:

Oakville Assembly Plant, Ontario, Canada

Discontinuation:

Discontinued after the 2007 model year, with Ford exiting the minivan market in North America.

🏆 Awards & Recognition

Common Awards:

While the Freestar itself did not garner significant individual awards, its platform shared underpinnings with vehicles that received positive reviews for comfort and utility. The manual is essential for maintaining these aspects.

Safety Ratings Context:

NHTSA ratings varied by drivetrain (FWD generally better for rollover than AWD). The manual provides detailed safety system maintenance and repair procedures.

Certification Context:

Not applicable for a service manual itself, but the manual's accuracy reflects Ford's OEM specifications and procedures.