Ford FREESTAR 2004-2007 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Freestar Year: 2004-2007 Vehicle Type: Minivan Codes Platform Code: Ford U platform (facelifted Mercury Monterey) 👋 Introduction Market Position Segment: Full-size Minivan Target...

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标签: 2004 2005 2006 2007 Car Cars Ford FREESTAR

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Description

🏷️ Basic Information

Identification

Make:

Model:

Freestar

Year:

2004-2007

Vehicle Type:

Minivan

Codes

Platform Code:

Ford U platform (facelifted Mercury Monterey)

👋 Introduction

Market Position

Segment:

Full-size Minivan

Target Audience:

Families, fleet operators, DIY mechanics.

Competitive Analysis

Key Competitors:

Dodge Grand Caravan, Chrysler Town & Country, Honda Odyssey, Toyota Sienna.

Key Features

Vehicle Attributes:

Spacious interior, comfortable ride, available all-wheel drive (AWD) on select models, versatile seating configurations.

Manual Purpose:

Provide comprehensive diagnostic, repair, and maintenance information for Ford Freestar vehicles of the specified model years.

📋 Manual Details

Coverage Areas

Market Segment:

North America

Language:

English

Page Count

Estimated Page Count:

1500-2000+

Manual Type

Manual Type:

Factory Service Manual (FSM)

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Drivetrain (Front-Wheel Drive)

Chassis:

Suspension (Front & Rear), Steering, Brakes (ABS, Parking Brake)

Electrical:

Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, HVAC Controls, Audio System, Power Accessories (Windows, Locks, Seats), Instrument Cluster, Diagnostic Trouble Codes (DTCs)

Body:

Exterior Panels, Interior Trim, Doors, Liftgate, Seats, HVAC Ducting

Procedures Included

Maintenance:

Fluid Changes (Engine Oil, Coolant, Transmission Fluid, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Cabin), Spark Plug Replacement, Belt Inspection/Replacement, Tire Rotation

Diagnostics:

Systematic Troubleshooting Flowcharts, DTC Interpretation, Component Testing Procedures, Wiring Diagrams

Repair:

Component Removal & Installation (Engine, Transmission, Suspension Components, Brake Calipers, Starter, Alternator), Body Panel Repair, Interior Trim Repair, HVAC Component Replacement

Diagnostics Advanced:

PCM Reprogramming, Sensor Calibration, CAN Bus Diagnostics

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to major component overhauls and advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Print Quality:

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

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

3.9L V6 (VIN 2), 4.2L V6 (VIN U)

Displacement:

3.9 Liters / 238 Cubic Inches (Base), 4.2 Liters / 256 Cubic Inches (Optional)

Performance

Horsepower 3.9L:

193 HP @ 4500 RPM

Torque 3.9L:

245 lb-ft @ 3000 RPM

Horsepower 4.2L:

203 HP @ 4800 RPM

Torque 4.2L:

260 lb-ft @ 3700 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Engine Management

Ford PCM (Powertrain Control Module)

🔧 Transmission

Standard

Transmission Type Standard:

4-Speed Automatic Overdrive

Transmission Code Standard:

4F50N

Optional

Transmission Type Optional:

4-Speed Automatic Overdrive with All-Wheel Drive (AWD)

Transmission Code Optional:

4F50N AWD

Features

Torque Converter:

Lock-up torque converter for improved fuel efficiency

Fluid Specifications

Transmission Fluid Type:

Mercon V Automatic Transmission Fluid

Fluid Capacities

Transmission Fluid Capacity Qt:

Approx. 11.3 quarts (10.7 liters) - Dry Fill

📐 Dimensions

Exterior

Length In:

201.1

Width In:

Height In:

Wheelbase In:

118.5

Front Track In:

Rear Track In:

Interior

Passenger Volume Cu Ft:

164.3

Cargo

Cargo Volume Behind 3Rd Row Cu Ft:

Cargo Volume Behind 2Nd Row Cu Ft:

Cargo Volume Behind 1St Row Cu Ft:

145.0

Weights

Curb Weight Lbs Min:

Gross Vehicle Weight Rating Gvwr Lbs:

5800-6050 (varies by configuration)

Towing Capacity Lbs:

Up to 3500 lbs (with optional towing package)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

★★★★☆ (4/5 Stars)

NHTSA Frontal Passenger:

★★★★☆ (4/5 Stars)

IIHS Offset Frontal:

Acceptable

Active Features

Standard 4-Wheel Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Electronic Stability Control:

Optional AdvanceTrac (Electronic Stability Control)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional side-impact airbags

Seatbelts:

3-point seatbelts for all seating positions, pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium audio systems with CD changer, and rear-seat entertainment systems.

Navigation:

Optional factory-installed navigation system available on higher trim levels.

Driver Assistance

Parking Sensors:

Optional rear parking assist sensors.

Cruise Control:

Standard cruise control.

Connectivity

Aux Input:

Auxiliary audio input jack available on some models.

Remote Start:

Optional remote keyless entry and remote start system.

🔧 Maintenance

Service Intervals

Oil Change Miles:

Every 5,000 miles or 6 months, whichever comes first.

Tire Rotation Miles:

Every 5,000 miles

Engine Air Filter Miles:

Inspect every 15,000 miles, replace as needed. Replace every 30,000 miles.

Cabin Air Filter Miles:

Inspect every 15,000 miles, replace as needed. Replace every 15,000-30,000 miles depending on driving conditions.

Spark Plug Replacement Miles 3.9L:

Platinum: 100,000 miles. Iridium: 100,000 miles (if specified).

Spark Plug Replacement Miles 4.2L:

Platinum: 100,000 miles.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic Blend or Full Synthetic

Engine Oil Capacity Qt 3.9L:

5.0 quarts (4.7 liters) with filter change

Engine Oil Capacity Qt 4.2L:

5.0 quarts (4.7 liters) with filter change

Coolant Type:

Ford Premium Long Life Coolant (Green or Orange depending on original fill, compatible)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Mercon V or equivalent

Known Issues

Transmission Reliability:

Some reports of transmission hard shifting, slipping, or failure, often related to fluid contamination or torque converter issues.

Engine Mounts:

Premature wear or failure of engine and transmission mounts, leading to excessive vibration.

Rear Suspension Springs:

Sagging or broken rear suspension springs, particularly on higher mileage vehicles.

Power Sliding Doors:

Issues with the power sliding door mechanisms, including motors, cables, and sensors.

HVAC Blend Door Actuators:

Failure of HVAC blend door actuators can lead to improper air temperature control or air distribution.

PCM Failure:

Occasional reports of Powertrain Control Module (PCM) failure, often requiring replacement and reprogramming.

📚 Vehicle History

Brand Heritage

Ford Legacy:

Ford has a long history in the minivan segment, dating back to the Ford Aerostar.

Model Evolution

Predecessor:

Ford Windstar

Development:

The Freestar was a significant facelift and rebranding of the Ford Windstar, incorporating updated styling, interior features, and powertrain refinements. It was also heavily related to the Mercury Monterey.

Production

Production Years:

2004-2007

Manufacturing Plant:

Oakville Assembly Plant, Ontario, Canada

Discontinuation Reason:

Sales declined significantly, and Ford shifted focus to SUVs and crossovers.

🏆 Awards & Recognition

Recognitions

Family Car Awards:

While the Freestar itself did not garner significant individual awards, its predecessors (Windstar) and contemporaries often received recognition in family vehicle categories for space and practicality.

Ratings

Consumer Reports Ratings:

Generally received average to below-average ratings for reliability and predicted owner satisfaction compared to segment leaders.

Certifications

Emission Standards:

Designed to meet EPA and California emission standards for the respective model years.