Ford Freestar 2004 to 2007 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Freestar Generation: First Generation Codes Platform Code: [,-] 👋 Introduction Market Position Target User: DIY enthusiasts and professional technicians seeking detailed repair and...

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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

Generation:

First Generation

Codes

Platform Code:

👋 Introduction

Market Position

Target User:

DIY enthusiasts and professional technicians seeking detailed repair and maintenance information.

Competitive Analysis

Advantage:

Provides dealership-level diagnostic and repair procedures, offering a significant advantage over generic repair guides.

Key Features

Dealer Level Info:

This manual is the exact same resource used by authorized Ford dealership technicians, ensuring accuracy and completeness.

Comprehensiveness:

Covers all service and repair aspects, from routine maintenance to complex overhauls, offering a complete solution for vehicle care.

Accessibility:

Available as a free download with no shipping costs, making it an extremely cost-effective resource.

📋 Manual Details

Coverage Areas

Applicability:

Ford Freestar 2004, 2005, 2006, 2007 model years

Page Count

Estimated Pages:

Extensive (typical factory workshop manuals for this era exceed 2000 pages)

Manual Type

Type:

Factory Service Workshop Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Electrical, Fuel System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle

Chassis:

Suspension System, Steering System, Restraint System, Brake System

Body:

Body (Interior and Exterior), Body Electrical System

Comfort:

Heating, Ventilation, Air Conditioning (HVAC)

Emissions:

Emission Control System

Procedures Included

General Maintenance:

Oil changes, fluid checks and replacements, filter changes, tire rotation

Engine Repair:

Engine mechanical repairs, cylinder head service, piston and connecting rod service, crankshaft service, timing system repair, engine rebuilding

Transmission Repair:

Manual transaxle overhaul, automatic transaxle overhaul and repair

Brake System Repair:

Brake pad replacement, rotor service, caliper overhaul, brake line repair, ABS system diagnostics and repair

Suspension Steering Repair:

Shock absorber and strut replacement, ball joint service, tie rod end replacement, power steering system repair

Electrical Diagnostics:

Wiring diagrams, component testing, diagnostic trouble code (DTC) interpretation, module programming

Body Work:

Interior and exterior trim removal/installation, panel repair, door and window mechanisms

HVAC Repair:

Component replacement (compressor, condenser, evaporator), refrigerant system service, diagnostic procedures

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete system overhauls and advanced diagnostics

📊 Manual Specifications

File Format

Quality:

PDF format ensures high quality, searchable text, and ease of navigation. Likely includes printable pages.

Print Quality

Digital Quality:

High resolution, clear diagrams, and easily readable text, mirroring factory specifications.

Binding Type

Digital Binding:

N/A (Digital PDF format)

Paper Type

Digital Paper:

N/A (Digital PDF format)

Compatibility

Operating Systems:

Windows (95/98/ME/XP/Vista/7), Linux, MAC

⚙️ Engine Specifications

Primary Engine

Engine Options:

The Ford Freestar was typically offered with V6 engines. Common options included:

3.9L V6 (3904Cc):

Displacement: 3.9 Liters (approx. 238 cubic inches). Often referred to as the '3.9L Vulcan' or 'SOHC V6'. Power output typically around 193-201 horsepower and 220-240 lb-ft of torque.

4.2L V6 (4163Cc):

Displacement: 4.2 Liters (approx. 254 cubic inches). This was a common engine for larger Ford vehicles. Power output typically around 201-205 horsepower and 260-270 lb-ft of torque.

4.0L V6 (3986Cc):

Displacement: 4.0 Liters (approx. 243 cubic inches). Ford's 'Cologne' V6, used in some earlier models. Power output around 195-200 horsepower and 230-240 lb-ft of torque.

Performance

Horsepower Range:

Approximately 193-205 hp, depending on the specific V6 engine option.

Torque Range:

Approximately 220-270 lb-ft, depending on the specific V6 engine option.

Fuel System

Injection Type:

Electronic Fuel Injection (EFI), likely Sequential Multi-Port Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline.

Engine Mechanical

Valvetrain:

Overhead Valve (OHV) for the 4.2L and older 3.9L, and Single Overhead Cam (SOHC) for the later 3.9L V6.

🔧 Transmission

Standard

Transmission Type:

Automatic Transaxle only. The Freestar was exclusively offered with an automatic transmission.

Optional

Manual Option:

None. No manual transmission was available for the Ford Freestar.

Features

Automatic Transmission Model:

Likely the Ford 4F50N or a similar 4-speed automatic transaxle, common in Ford/Mercury vehicles of this era.

Transmission Fluid:

Mercon V is the specified automatic transmission fluid for the 4F50N and similar transmissions. Refer to the manual for exact capacities and change intervals.

📐 Dimensions

Exterior

Body Style:

Minivan

Length:

Approximately 200.5 inches

Width:

Approximately 79.3 inches

Height:

Approximately 68.6 inches

Interior

Seating Capacity:

Available in 6, 7, or 8-passenger configurations.

Cargo

Cargo Volume Behind 3Rd Row:

Approximately 20.2 cubic feet

Cargo Volume Behind 2Nd Row:

Approximately 65.5 cubic feet

Cargo Volume Behind 1St Row:

Approximately 133.4 cubic feet

Weights

Curb Weight:

Typically ranges from 4,400 to 4,800 lbs, depending on configuration and engine.

Gross Vehicle Weight Rating (Gvwr):

Typically around 5,900 - 6,000 lbs.

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test Rating:

4-star rating for driver and front passenger (2004 model year).

IIHS Side Impact Crash Test Rating:

Good rating (2004 model year).

Active Features

Standard Anti-lock Braking System (ABS) on all four wheels.

Traction Control:

Optional Traction Control System (TCS).

Electronic Stability Control:

Optional Electronic Stability Control (ESP), often bundled with other advanced features.

Passive Features

Airbags:

Standard front airbags for driver and front passenger. Optional side-impact airbags, and available overhead curtain airbags for all three rows.

Seat Belts:

Three-point seat belts with pretensioners for all seating positions. LATCH (Lower Anchors and Tethers for Children) system.

Child Safety Locks:

Standard rear door child safety locks.

💡 Technology Features

Infotainment

Audio System:

Available with AM/FM stereo, CD player, and optional premium sound systems. Some models may have had satellite radio capability.

Rear Seat Entertainment:

Optional rear-seat entertainment system, typically including a DVD player and video screens.

Driver Assistance

Parking Sensors:

Optional rear parking assist sensors.

Backup Camera:

Less common in this era, but some later models or aftermarket installations may have featured a backup camera.

Connectivity

Auxiliary Input:

May have an auxiliary audio input jack for connecting portable media devices.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 to 7,500 miles or 6 months, whichever comes first, using synthetic blend or full synthetic oil. Consult the manual for precise recommendations based on driving conditions.

Tire Rotation:

Recommended every 5,000 to 7,500 miles.

Transmission Fluid Change:

Recommended around every 30,000 to 60,000 miles for automatic transmissions, depending on driving conditions. Crucial for longevity. The manual will specify exact intervals and procedures.

Coolant Flush:

Typically every 30,000 to 50,000 miles or 2 to 5 years. Refer to the manual for specific coolant type and interval.

Fluid Specifications

Engine Oil:

SAE 5W-20 is the most common viscosity for Ford V6 engines of this era. Check the oil fill cap or manual for confirmation. Capacity typically around 5-6 quarts.

Coolant:

Ford Premium Gold Coolant (or equivalent) is typically specified. A 50/50 mix of coolant and distilled water is standard.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Mercon ATF or a specific Ford power steering fluid, depending on the system. Consult the manual.

Known Issues

Transmission Problems:

Some owners have reported issues with the automatic transmission, including rough shifting or premature wear. Regular fluid changes are critical.

Suspension Wear:

Components like ball joints, tie rod ends, and struts can experience wear over time, leading to steering or ride quality issues.

Power Steering Leaks:

Potential for leaks in the power steering system, particularly at hoses or the pump.

Rear Air Suspension Issues:

Models equipped with rear air suspension may experience leaks or compressor failures.

📚 Vehicle History

Brand Heritage

Manufacturer:

Ford Motor Company, a long-standing American automotive manufacturer with a history dating back to 1903.

Model Evolution

Predecessor:

The Ford Freestar replaced the Ford Windstar minivan in Ford's lineup.

Generation Designation:

This represents the first and only generation of the Ford Freestar, produced from 2004 to 2007.

Production

Production Years:

2004, 2005, 2006, 2007.

Manufacturing Location:

Oakville Assembly Plant, Oakville, Ontario, Canada.

Discontinuation:

Production of the Freestar ended in 2007 without a direct replacement, as Ford shifted its minivan strategy.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Received positive safety ratings from organizations like NHTSA and IIHS for its crashworthiness, particularly in frontal and side impacts.

Ratings

Consumer Ratings:

Consumer reviews were mixed, with some praising its utility and comfort, while others noted reliability concerns common in minivans of this class.