🏷️ Basic Information

Make:

Ford

Model:

Freestar

Year:

2004-2007

Platform:

Ford Freestar / Mercury Monterey (D4 platform)

Chassis Code:

U90

👋 Introduction

Segment:

Full-size minivan

Competitors:

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

Body Styles:

Long and Short Wheelbase (SWB/LWB) minivans.

Seating Capacity:

Available in 7-passenger and 8-passenger configurations.

Interior Versatility:

Stow 'n Go seating (optional on some trims) offered enhanced cargo and passenger flexibility.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Powertrain Control, Diagnostics, Maintenance, Troubleshooting, Repair Procedures, Wiring Diagrams, Specifications, Component Locations.

Estimated Pages:

2000+

Type:

Factory Service Manual / Shop Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

3.9L V6 (237ci) and 4.2L V6 (256ci) Vulcan engines. Engine assembly, disassembly, lubrication, cooling, fuel system, ignition system, emissions, starting, charging.

Transmission Powertrain:

4-Speed Automatic Transaxle (4F50N). Transmission overhaul, diagnosis, repair, fluid specifications, torque converter.

Drivetrain:

Front Wheel Drive (FWD) system. Axles, CV joints, differential components, wheel bearings.

Suspension:

Independent front suspension (MacPherson struts), rear beam axle with coil springs. Springs, shock absorbers, control arms, ball joints, bushings, alignment procedures.

Steering:

Power-assisted rack and pinion steering. Steering column, steering gear, power steering pump, fluid specifications.

Brakes:

Front disc brakes, rear drum brakes (standard). ABS system, hydraulic lines, master cylinder, calipers, brake pads, rotors, drums, parking brake.

Electrical System:

Battery, charging system, starting system, lighting, instrument cluster, body control module (BCM), power distribution, infotainment system wiring.

HVAC:

Air conditioning, heating, ventilation. Components, refrigerant, diagnosis, repair, blower motor, evaporator, condenser.

Body And Interior:

Body panels, doors, hood, liftgate, interior trim, seating, glass, exterior moldings, structural components.

Powertrain Control Modules:

PCM (Powertrain Control Module) and TCM (Transmission Control Module) diagnostics, programming, and repair.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, brake service, tire rotations, belt inspections.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, using symptom-based charts and diagnostic trouble codes (DTCs).

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major vehicle systems.

Diagnostics:

OBD-II diagnostics, scan tool usage, live data interpretation, circuit testing, component testing.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all circuits, including component locations and connector views.

Depth:

Comprehensive. Covers everything from basic fluid changes to complete engine and transmission overhauls, advanced electrical diagnostics, and body repair.

📊 Manual Specifications

File Type:

PDF

Searchability:

Text-searchable PDF for quick information retrieval.

Printable:

Printable pages for workshop use.

Resolution:

High-resolution images, diagrams, and text for clarity.

Binding:

N/A (Digital format)

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Engine 1 Type:

3.9L V6 (237ci) Vulcan

Engine 1 Displacement:

3949 cc

Engine 1 Bore X Stroke:

94.0 mm x 93.0 mm

Engine 1 Compression Ratio:

9.0:1

Engine 1 Horsepower:

175 hp @ 4500 rpm (approx.)

Engine 1 Torque:

220 lb-ft @ 3000 rpm (approx.)

Engine 2 Type:

4.2L V6 (256ci) Vulcan

Engine 2 Displacement:

4203 cc

Engine 2 Bore X Stroke:

94.0 mm x 100.0 mm

Engine 2 Compression Ratio:

9.0:1

Engine 2 Horsepower:

200 hp @ 4300 rpm (approx.)

Engine 2 Torque:

270 lb-ft @ 3000 rpm (approx.)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Ignition System:

Distributorless Electronic Ignition (DIS) or Coil-on-Plug (COP) depending on specific engine and model year.

🔧 Transmission

Type:

4-Speed Automatic Transaxle (4F50N)

Type:

N/A (4F50N was standard across all engines/trims)

Drive Type:

Front Wheel Drive (FWD)

Transmission Fluid Type:

Mercon V

Control Module:

Transmission Control Module (TCM) integrated with PCM or separate unit.

📐 Dimensions

Wheelbase Swb:

118.8 inches (3018 mm)

Wheelbase Lwb:

131.5 inches (3340 mm)

Length Swb:

199.5 inches (5067 mm)

Length Lwb:

212.2 inches (5390 mm)

Width:

77.4 inches (1966 mm)

Height:

68.5 inches (1740 mm)

Cargo Volume Behind 3Rd Row Swb:

31.1 cu ft (approx.)

Cargo Volume Behind 3Rd Row Lwb:

46.0 cu ft (approx.)

Curb Weight Est:

4,300 - 4,700 lbs (approx.)

Gross Vehicle Weight Rating Gvwr Est:

5,600 - 6,200 lbs (approx.)

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (2004 model year)

NHTSA Front Impact Passenger:

4 Stars (2004 model year)

NHTSA Side Impact Front Seat:

4 Stars (2004 model year)

NHTSA Side Impact Rear Seat:

5 Stars (2004 model year)

IIHS Frontal Offset:

Good (2004 model year)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System

Airbags:

Front airbags, available front side-impact airbags.

Seatbelts:

3-point seatbelts with pretensioners for all seating positions.

Child Safety:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio Systems:

Available AM/FM stereo with CD player, cassette player, and premium audio systems with subwoofer.

Rear Seat Entertainment:

Optional rear-seat entertainment system with video screen and headphone jacks.

Parking Sensors:

Available rear parking assist system.

Power Outlets:

Standard 12V power outlets.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (using recommended synthetic blend or full synthetic oil).

Air Filter Replacement:

Every 30,000 miles or 24 months.

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

4.2L V6: 100,000 miles (Long-Life Spark Plugs). 3.9L V6: Consult manual, typically 60,000-100,000 miles depending on plug type.

Transmission Fluid Change:

Every 100,000 miles or as needed based on driving conditions and fluid condition.

Engine Oil Type:

SAE 5W-20 (preferred) or SAE 5W-30

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter for 3.9L V6; 5.0 US quarts (4.7 L) with filter for 4.2L V6.

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent.

Coolant Capacity:

Approx. 14.0 US quarts (13.2 L)

Transmission Reliability:

The 4F50N transmission can be prone to torque converter shudder and internal component wear if not properly maintained. The manual provides detailed diagnosis and repair for these issues.

Ignition System:

Coil-on-plug (COP) ignition systems can experience coil failure. The manual details testing and replacement procedures.

Power Steering:

Leaks from the power steering system or failing pumps can occur. The manual covers diagnosis, repair, and fluid specifications.

Rear Suspension:

Rear spring sag or broken springs have been reported. The manual provides replacement and troubleshooting guidance.

📚 Vehicle History

Manufacturer:

Ford Motor Company

Predecessor:

Ford Windstar

Rebranding:

The Freestar replaced the Ford Windstar and shared its platform with the Mercury Monterey.

Production Years:

2004-2007

Assembly Location:

Oakville Assembly Plant, Ontario, Canada

🏆 Awards & Recognition

Safety Awards:

Received 4-star and 5-star safety ratings from NHTSA in frontal and side impact tests for the 2004 model year. IIHS frontal offset rating was 'Good'.

Awards Summary:

While the Freestar aimed to compete, it generally received mixed reviews, with strengths in safety and utility but criticisms often directed at its powertrain and handling compared to segment leaders.