2004 Ford Freestar Fuel system Problems
- Complaints
- 23about this part
- Share
- 2%of 1,227 total for the year
- Median mileage
- 87,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 23 complaints about the fuel system of the 2004 Ford Freestar, 2% of the 1,227 complaints for this model year. Where a mileage was given, the median is 87,000 miles. 1 of these say a crash was involved, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Every single time gas is being pumped into the car the pump stops several times. It can take up to 20 minutes to completely fill the gas tank. Not only does it just stop, it frequently spits gas back out. The gas, which is a chemical, has given at least 2 people chemical burns on multiple occasions. Ford has been contacted and while this is a known issue , they refuse to replace and/or repair unless I pay for it out of my pocket. …”
NHTSA complaint #10480864, filed 2012-10, 50,000 miles“Just purchased this used 2004 Freestar. Within days the engine would fail while driving. Transmission shifting issues. Not starting. Etc.. Had transmission replaced before knowing of recall on that item. Still had the issues. Pulled out PCM and it was filled with water. Installed new one. I live in florida. Rainy season. Issues happened again within a week. New PCM removed and was filled with water. I myself found the service bulletin about the issue as well as several complaints by owners on the internet. …”
NHTSA complaint #10563998, filed 2014-02, 117,000 miles“Intermittently, when I am idling in drive (like at a light) with my foot on the brake, the van will begin to surge and lurch forward, sometimes violently. Only pressing hard on the brake will keep it from moving forward and causing a crash. Sometimes happens in reverse also. The tachometer will surge up to higher rpms and back down as it lurches. Sometimes, if it is violent enough, the battery light will flash off and on as if the vehicle is about to stall. Seems very dangerous as it could cause an accident with a nearby vehicle.”
NHTSA complaint #10541999, filed 2013-09, 124,000 miles“This is the second issue I have had with water getting into the PCM(computer). The first occurrence (03/10) I had the car towed to the Ford dealership and was advises per the obdb scan codes that the transmission needed an overhaul. I told the dealership that I had just pulled the car out of my driveway and had no reverse and had slippage in other gears, it was raining very heavily that day- I asked the dealership if it could be an issue of moisture getting into PCM(computer), the dealership said that that was not the issue. …”
NHTSA complaint #10397763, filed 2011-04, 88,842 miles“Bad EGR valve. Ordered part 6 weeks ago and keep getting told the part is on back order, have called other dealers, they have said they will have the part but never get it. This vehicle is a primary car and it has been out for 2 months now. What am I supposed to do with a vehicle that I can't drive because I cant get the part to get it fixed? I have two friends with the same vehicle, similar miles but their the 05 model with the same problem, cant get the part either.”
NHTSA complaint #10210744, filed 2007-12, 84,100 milesFuel system: other model years
Other parts of the 2004 Ford Freestar
851 complaintsElectrical system
118 complaintsBody and structure
94 complaintsSeats
86 complaintsEngine
69 complaintsBrakes
59 complaintsEngine cooling
49 complaintsVehicle speed control
33 complaintsOther or unknown
29 complaintsSteering
27 complaintsSuspension
25 complaintsWheels
25 complaints
← All problems reported for the 2004 Ford Freestar
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology