Segment:
Full-size minivan
Target Audience:
Families, individuals requiring flexible passenger and cargo transport
Key Competitors:
Chevrolet Uplander/Venture, Buick Terraza, Pontiac Montana/SV6, Chrysler Town & Country/Dodge Grand Caravan, Toyota Sienna, Honda Odyssey
Manual Benefit 1:
Provides the exact information dealership technicians use, ensuring accuracy and efficiency.
Manual Benefit 2:
Enables DIY repairs, saving significant money on labor costs.
Manual Benefit 3:
Facilitates understanding of vehicle systems for better ownership and maintenance.
Format Advantage:
Single, easily navigable PDF file with printable pages for workshop use.
Powertrain:
Engine, Control System, Fuel Service, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition, Starting/Charging, Automatic Transmission, Manual Transmission, Transfer Case, Drive Shaft, Differential, Axles
Chassis:
Suspension, Tire & Wheel, Brake Control, Brakes, Parking Brake, Steering Column, Power Steering
Body & Electrical:
Air Conditioning, Supplemental Restraint System (SRS), Seat Belts, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Locks, Meter/Audio/Visual, Horn, Windshield/Glass/Mirrors, Instrument Panel, Seats, Engine Hood/Doors, Exterior & Interior, Electrical Systems, Multiplex/CAN Communication
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), component testing
Repair:
Step-by-step repair procedures for all covered systems, including component removal, installation, and adjustment
Electrical Diagnostics:
Wiring schematics, connector pinouts, circuit descriptions, diagnostic procedures for electrical components and systems
Depth:
Comprehensive: Covers basic maintenance to advanced diagnostics and complete component overhaul. Includes factory specifications, tolerances, and procedures.
Engine Type:
3.9L (3895cc) OHV 12-valve V6 (Ford 'Montreal' Vulcan engine)
Horsepower:
201 hp @ 5000 rpm (for 3.9L engine)
Torque:
240 lb-ft @ 3250 rpm (for 3.9L engine)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Port Injection (SPI)
Fuel Type:
Unleaded gasoline
Oil Type:
SAE 5W-20 synthetic blend (API Service SN or higher recommended, check manual for specific spec)
Oil Capacity:
5.8 US quarts (5.5 liters) with filter change (for 3.9L V6)
Transmission Type:
4-speed automatic overdrive
Transmission Type:
N/A (Only automatic was offered)
Transmission Control:
Electronic with Overdrive (Electronic Controlled Transmission - ECT)
Transmission Fluid Type:
Mercon V (Automatic Transmission Fluid)
Transmission Fluid Capacity:
Approx. 12.1 US quarts (11.4 liters) for a dry fill/rebuild (check manual for drain and fill capacity)
Length:
202.2 inches (5136 mm)
Width:
77.4 inches (1966 mm)
Height:
68.1 inches (1730 mm)
Wheelbase:
120.0 inches (3048 mm)
Curb Weight:
4,300 - 4,500 lbs (1950 - 2041 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:
5,740 - 6,000 lbs (2604 - 2722 kg) depending on configuration
NHTSA Frontal Crash Driver:
★★★★☆ (4/5 stars)
NHTSA Frontal Crash Passenger:
★★★★☆ (4/5 stars)
NHTSA Side Impact Driver:
★★★★★ (5/5 stars)
NHTSA Side Impact Passenger:
★★★★★ (5/5 stars)
NHTSA Side Impact Rear Passenger:
★★★★★ (5/5 stars)
IIHS Front Offset Crash:
Acceptable
IIHS Side Impact Crash:
Good
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Airbags Front:
Standard front driver and passenger airbags
Airbags Side:
Available front seat-mounted side airbags, available third-row side curtain airbags
Seat Belts:
Three-point seat belts for all seating positions, LATCH system for child seats
Audio System:
Available AM/FM stereo with CD player, MP3 capability, auxiliary input jack. Premium audio systems with amplifiers were also optional.
Rear Seat Entertainment:
Available rear-seat entertainment system with DVD player and screens.
Parking Assist:
Available rear parking assist sensors.
Connectivity Features:
Limited connectivity features by modern standards. Primarily focused on audio and basic vehicle information displays.
Oil And Filter Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Severe duty may require more frequent changes. Consult manual for exact intervals.
Engine Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or at least every 30,000 miles (48,000 km).
Cabin Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or at least every 30,000 miles (48,000 km).
Transmission Fluid Change Interval:
Inspect every 30,000 miles (48,000 km), change at 60,000 miles (96,000 km) or as indicated by severe usage conditions. Consult manual for specific interval and Mercon V specification.
Coolant Type:
Ford Gold Coolant (or equivalent silicate-free OAT coolant)
Power Steering Fluid:
Ford Power Steering Fluid (or equivalent meeting Ford specification, consult manual)
Brake Fluid:
DOT 3 brake fluid
Common Issue 1:
Transmission problems: Early models sometimes experienced transmission issues, including harsh shifting and premature wear. The manual will detail diagnostics and repair procedures for this.
Common Issue 2:
Heater core leaks: Some Freestar models have reported heater core leaks, leading to coolant loss and fogging of the windshield. The manual covers heater core removal and replacement.
Common Issue 3:
Suspension noise: Front suspension components, such as ball joints or sway bar links, can develop noise over time. The manual provides specifications for inspection and replacement.
Common Issue 4:
Powertrain Control Module (PCM) issues: In some instances, PCM failures or software glitches have been reported, affecting engine performance and drivability. The manual guides technicians in diagnosing and reprogramming/replacing the PCM.
Ford Van History:
Ford has a long history of producing minivans, starting with the Aerostar and later the Windstar, leading to the Freestar.
Freestar Predecessor:
The Freestar replaced the Ford Windstar, sharing the same platform but with updated styling, features, and improved safety.
Platform Origin:
The Ford W platform was developed by Ford and is shared with contemporary SUVs and vans from Ford and its partners.
Production Start Year:
2004
Production End Year:
2007
Assembly Location:
Oakville Assembly Plant, Ontario, Canada
Safety Awards:
Received good safety ratings from IIHS and NHTSA for side-impact protection, indicating a strong safety structure.
Consumer Reviews General:
Mixed reviews, often praised for interior space and comfort but sometimes criticized for powertrain refinement and build quality compared to competitors.
