🏷️ Basic Information

Make:

Ford

Model:

Freestar

Model Years Covered:

2004, 2005, 2006, 2007

Vehicle Type:

Minivan

Platform:

Ford W platform

👋 Introduction

Vehicle Segment:

Full-size minivan

Target Audience:

Families requiring spacious and versatile transportation.

Key Competitors:

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

Vehicle Highlights:

Spacious interior, flexible seating configurations, optional all-wheel drive, available V6 engines.

Benefit To Owner:

Empowers owners and independent mechanics with the knowledge to perform accurate diagnostics, repairs, and maintenance, potentially saving time and money.

📋 Manual Details

Coverage Scope:

Comprehensive workshop service and repair

Systems Included:

Engine, Transmission (Automatic), Drivetrain (FWD/AWD), Suspension, Steering, Brakes, Electrical System, HVAC, Body & Trim, Fuel System, Cooling System, Exhaust System, Emissions Control, Safety Systems (Airbags, ABS), Diagnostic Procedures, Wiring Diagrams

Estimated Pages:

Approx. 3000+ pages (depending on specific engine/drivetrain configurations)

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

Searchability:

Fully searchable PDF with hyperlinked table of contents for quick navigation.

Printability:

Printable pages for on-site workshop use.

📖 Manual Coverage

Engine Management:

Detailed diagnosis and repair for Powertrain Control Module (PCM), ignition system, fuel injection system, sensors (MAF, O2, TPS, Crankshaft/Camshaft Position), actuators, and emission controls.

Transmission Repair:

Complete overhaul procedures for the 4-speed automatic transmission (e.g., 4F50N), including valve body diagnosis, clutch pack replacement, torque converter service, and electronic controls.

Drivetrain Service:

Front-wheel drive (FWD) and All-wheel drive (AWD) system servicing, including CV axles, differential, transfer case (for AWD models), and driveshafts.

Suspension And Steering:

Front and rear suspension components (struts, shocks, control arms, ball joints, sway bars), power steering system diagnosis and repair (pump, rack and pinion), wheel alignment specifications.

Brake System:

Front and rear brake component replacement (pads, rotors, calipers), hydraulic system bleeding, Anti-lock Brake System (ABS) component testing and diagnosis.

Electrical And Lighting:

Complete wiring diagrams, fuse and relay identification, power distribution, charging system (alternator, battery), starting system, lighting systems (headlights, taillights, interior), power accessories (windows, locks, mirrors).

HVAC System:

Air conditioning (AC) system service (refrigerant, compressor, evaporator, condenser), heating system operation, climate control module diagnosis, blower motor and fan replacement.

Body And Interior:

Door panel removal, seat adjustment/replacement, dashboard disassembly, exterior trim replacement, glass replacement procedures.

Preventative Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, belt inspections/replacement.

Troubleshooting Guides:

Diagnostic flowcharts for common drivability issues, electrical faults, starting problems, braking concerns, and HVAC malfunctions.

Component Replacement:

Step-by-step instructions for replacing major components such as engines, transmissions, alternators, starters, water pumps, fuel pumps, radiators, A/C compressors, and power steering pumps.

Diagnostic Procedures:

On-Board Diagnostics (OBD-II) code interpretation, live data analysis, actuator testing, sensor testing using multimeters and oscilloscopes.

Rebuilding Procedures:

Detailed instructions for engine and transmission overhauls, including specifications for clearances, tolerances, and torque values.

Depth Of Information:

Extensive, covering from basic maintenance and routine servicing to complex diagnostics, component overhauls, and complete vehicle teardowns.

Diagnostic Capabilities:

Advanced diagnostic procedures, including wiring diagrams, component locations, and specific testing methods for electrical and mechanical systems.

📊 Manual Specifications

Type:

PDF

Resolution:

High-resolution scans for clear diagrams and text.

Physical Binding:

N/A (Digital Product)

Physical Paper:

N/A (Digital Product)

⚙️ Engine Specifications

Engine 1:

3.9L OHV V6

Engine 1 Displacement:

3900 cc (238 ci)

Engine 1 Power:

193 hp @ 4900 rpm

Engine 1 Torque:

240 lb-ft @ 3500 rpm

Engine 2:

4.2L OHV V6

Engine 2 Displacement:

4200 cc (256 ci)

Engine 2 Power:

203 hp @ 4800 rpm

Engine 2 Torque:

250 lb-ft @ 3500 rpm

Fuel Type:

Unleaded Gasoline

Induction:

Electronic Fuel Injection (EFI)

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug or coil pack configurations.

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle

Transmission Model Code:

4F50N

Drivetrain Options:

Front-Wheel Drive (FWD) and All-Wheel Drive (AWD)

Transmission Fluid Type:

Mercon V

Transmission Fluid Capacity:

Approx. 10.9 quarts (10.3 liters) for initial fill; 13.3 quarts (12.6 liters) for total capacity.

📐 Dimensions

Length:

Approx. 201.2 inches (5110 mm)

Width:

Approx. 78.5 inches (1994 mm)

Height:

Approx. 68.4 inches (1737 mm)

Wheelbase:

Approx. 123.5 inches (3137 mm)

Cargo Volume Behind 3Rd Row:

Approx. 22.6 cubic feet (0.64 cubic meters)

Cargo Volume Behind 2Nd Row:

Approx. 92.4 cubic feet (2.62 cubic meters)

Cargo Volume Behind 1St Row:

Approx. 142.1 cubic feet (4.02 cubic meters)

Curb Weight FWD:

Approx. 4400 - 4600 lbs (1996 - 2087 kg)

Curb Weight AWD:

Approx. 4500 - 4700 lbs (2041 - 2132 kg)

🛡️ Safety Features

NHTSA Frontal Crash Rating:

4-star (Driver), 4-star (Passenger)

NHTSA Side Impact Rating:

4-star (Front), 5-star (Rear)

IIHS Rollover Rating:

Good

ABS:

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

Traction Control:

Optional Traction Control System (TCS) on some models.

Airbags:

Standard front-seat airbags. Optional side-curtain airbags for all three rows.

Seat Belts:

Three-point seatbelts with pretensioners for all seating positions.

💡 Technology Features

Available Systems:

AM/FM stereo with CD player, optional premium audio systems, rear-seat entertainment systems, navigation systems (late models).

Available Features:

Rear parking sensors, trailer sway control (optional).

Connectivity Options:

Basic auxiliary input jacks on some audio systems.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first, using synthetic blend or full synthetic oil.

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

3.9L V6: 100,000 miles (160,000 km); 4.2L V6: 100,000 miles (160,000 km) (if equipped with Iridium plugs).

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or 48 months for normal service; 30,000 miles (48,000 km) or 24 months for severe service.

Coolant Replacement:

Initial fill: 100,000 miles (160,000 km) or 5 years. Subsequent fills: Every 50,000 miles (80,000 km) or 2 years.

Engine Oil Specification:

API SG, SH, SJ, SL rated, SAE 5W-20 (preferred) or 5W-30.

Engine Coolant Specification:

Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B44-D2.

Power Steering Fluid:

Ford Power Steering Fluid or an equivalent meeting specification ESW-M2C195-A.

Common Problems:

Transmission shudder or failure (especially 4F50N), front suspension wear (ball joints, control arm bushings), AC system leaks, rear shock absorber leaks, power sliding door malfunctions, catalytic converter failure.

Diagnostic Tips:

Transmission fluid level and condition are critical. Check for DTCs related to transmission solenoids or pressure sensors. Listen for clunks/rattles from suspension components.

📚 Vehicle History

Ford Minivan History:

Ford's entry into the minivan segment evolved from the Aerostar, with the Freestar being a significant redesign and rebranding.

Freestar Debut:

Introduced for the 2004 model year, replacing the Ford Windstar.

Design Basis:

Based on the updated W platform, sharing components with other Ford SUVs and minivans of the era.

Manufacturing Location:

Oakville Assembly Plant, Ontario, Canada.

Production End Year:

2007, succeeded by the Ford Taurus X (station wagon/crossover).

🏆 Awards & Recognition

Industry Awards:

Generally not a recipient of major industry awards compared to some competitors; often cited for its practicality and value.

Consumer Ratings:

Mixed consumer ratings, often reflecting reliability concerns with the transmission for some owners.