IllustrationAIR CONDITIONER, RIGHT SIDE PASSENGER DOOR WINDOW, MOTER MOUNTS. *TR
2006 Ford Freestar
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Freestar years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
1825–50K
4750–75K
9275–100K
105100–150K
38150K+
325 reports with mileage · 31 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Power Train. Review the 254 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 31 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
3 crash reports4 fire reports1 injury reports
Engine And Engine Cooling complaints
8 reportsEVERY TIME IT RAINED, MY ENGINE WOULD SHUDDER, SHAKE, SOMETIMES KNOCK, THE TRANSMISSION WOULD SHIFT FOR NO GOOD REASON, AND I STALLED OUT IN TRAFFIC ONCE. THE VEHICLE BECAME NON-DRIVABLE WHEN IT RAINED (AND ONLY WHEN IT RAINED). I TOOK THE VEHICLE TO MY FORD DEALER (SCHULTS FORD OF HARMARVILLE, PA), WHERE TECHNICIAN PAT SAND I…
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EVERY TIME IT RAINED, MY ENGINE WOULD SHUDDER, SHAKE, SOMETIMES KNOCK, THE TRANSMISSION WOULD SHIFT FOR NO GOOD REASON, AND I STALLED OUT IN TRAFFIC ONCE. THE VEHICLE BECAME NON-DRIVABLE WHEN IT RAINED (AND ONLY WHEN IT RAINED). I TOOK THE VEHICLE TO MY FORD DEALER (SCHULTS FORD OF HARMARVILLE, PA), WHERE TECHNICIAN PAT SAND INDICATED THAT THIS IS A KNOWN PROBLEM WITH FORD FREESTARS, AND SAID A FORD SERVICE BULLETIN INDICATES THAT BECAUSE OF A MANUFACTURING PROBLEM (INCORRECT SEALER APPLICATION TO THE PCM AND POOR POSITION OF PCM IN RELATION TO WINDSHIELD RUN-OFF) WATER LEAKAGE INTO THE PROGRAM CONTROL MODULE CAUSES IT TO ISSUE RANDOM COMMANDS AND ERRORS. THEY FOLLOWED THE FORD BULLETIN AND BY SIMPLY BETTER SEALING AGAINST MOISTURE / BLOCKING THE WATER FLOW, RESOLVED THE PROBLEM. THIS IS A SAFETY ISSUE AND A KNOWN MANUFACTURING DEFECT. *TR
I OWN A 2006 FORD FREESTAR AND AS OF JAN 9 2012 THEY HAVE RECALLED 04-05 FOR THE TRANSMISSION BLOWING UP! TORQUE CONVERTER ,PUMP AND OUTPUT SHAFT TO GIVE YOU THE PATS! MY FAMILY WAS IN THE VAN ON THE 400 HWY DRIVING ON JAN 22 2012 WITH TWO CHILDREN AND MY VAN SHOUTS DOWN NO CONTROL,DRIVING 105-110 IN THE MIDDLE LANE.. WE DID GE…
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I OWN A 2006 FORD FREESTAR AND AS OF JAN 9 2012 THEY HAVE RECALLED 04-05 FOR THE TRANSMISSION BLOWING UP! TORQUE CONVERTER ,PUMP AND OUTPUT SHAFT TO GIVE YOU THE PATS! MY FAMILY WAS IN THE VAN ON THE 400 HWY DRIVING ON JAN 22 2012 WITH TWO CHILDREN AND MY VAN SHOUTS DOWN NO CONTROL,DRIVING 105-110 IN THE MIDDLE LANE.. WE DID GET TO THE SIDE OF THE ROAD AND NO ONE WAS HURT THANK GOD, TO REALIZE OUR TRANSMISSION BLOW,WITH ONLY 105,000KM ON THE VAN NOT KNOWING THERE WAS A PROBLEM OUT FROM FORD CANADA ALL READY FOR THE 04-05 ,WE HAVE CALLED FORD CANADA AND TOLD THEM WHAT HAPPENED AND THEY INFORMED US THAT WE HAVE NO WARRANTY AND ITS NOT IN THE RECALLS, SO THE VAN WAS FIXED WITH A BILLOF 2975.00AT AAMCO TRANSMISSION ON JAN 25TH 2012 WITH NO HELP FROM FORD, I CANT BELIEVE THIS HAS HAPPENED THEY WERE AWARE OF THIS PROBLEM AND ARE NOT CONCERNED ABOUT LIVES, SOMEONE OR ALL OF US AND ANYONE AROUND US COULD HAVE LOST THERE LIVES DUE TO THIS PROBLEM WITH THE TRANSMISSIONS FAILING AND THERE KNOW ABOUT IT, AND DON'T FEEL THERE IS ENOUGH REPAIRED WITH THE 06 ARE YOU KIDDING ME NOT ENOUGH REPORTS THIS IS A JOKE, THERE ARE AWARE OF THIS AND WHEN SOMEONE LOSES THERE LIFE THERE RECALL THEM , GIVE YOUR HEAD A SHAKE, FIX THE PROBLEM BEFORE THIS EVEN HAPPENS, I DON'T KNOW WHERE TO BEGIN AND WHERE OR WHO TO TALK TO BUT I AM EMAIL EVERYONE I CAN SO THAT NO ONE LOSES THERE LIFE OVER THIS!!!I NEED HELP FROM ALL PARTIES OUT THERE PLEASE I AM HEARD THIS HAPPENED TO ME AND MY FAMILY AND IT COULD HAVE TURN OUT VERY BAD!!!!! *TR
BOUGHT THE 2006 FORD FREESTAR ON 9/14/11. 5 MINUTES AFTER THE PURCHASE, I CAME TO A LIGHT AND THE CAR LOST ALL POWER. TURNED RIGHT AROUND AND WENT BACK TO THE DEALERSHIP AND ASSUMED IT WAS FROM SITTING IN THE LOT THROUGH A MASSIVE SNOW STORM. IN THE 18 WEEKS THAT I HAVE HAD THE VEHICLE, IT HAS BEEN BROUGHT BACK TO THE SHOP 4 TIM…
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BOUGHT THE 2006 FORD FREESTAR ON 9/14/11. 5 MINUTES AFTER THE PURCHASE, I CAME TO A LIGHT AND THE CAR LOST ALL POWER. TURNED RIGHT AROUND AND WENT BACK TO THE DEALERSHIP AND ASSUMED IT WAS FROM SITTING IN THE LOT THROUGH A MASSIVE SNOW STORM. IN THE 18 WEEKS THAT I HAVE HAD THE VEHICLE, IT HAS BEEN BROUGHT BACK TO THE SHOP 4 TIMES TOTALING 12 FULL WEEKS. WE HAVE CONSTANT LOSS OF POWER. WE ALSO EXPERIENCE A JERKING/BUCKING WHICH RESULTS IN THE ENGINE LIGHT FLASHING AND AS SOON AS THE CAR SLOWS DOWN ENOUGH, IT WILL LOSE POWER. THIS USUALLY HAPPENS RIGHT AFTER RAIN. THESE PROBLEMS HAVE LEFT ME WITH A NON MOBILE CAR IN INTERSECTIONS. THIS IS NOT SAFE AT ALL AND THERE SHOULD BE A RECALL ON THIS VEHICLE BEFORE SOMEONE ENDS UP IN A FATAL CRASH. *TT
AT START-UP ENGINE MISFIRES. HESITATION. RE-TRY 1 TO 2 TIMES AND THEN STARTS. VEHICLE PURCHASED AT USED CAR LOT. CAR HAS 30,000 MILES (48,000 KM). STILL UNDER POWER TRAIN WARRANTY BUT DEALER WANTS TO WAIT.............. DEALERS REPRESENT THE MANUFACTURER AND SHOULD BE MORE ACCOUNTABLE, ALONG WITH MANUFACTURER. *TR
HAVE OWNED THIS 2006 FREESTAR SINCE NEW. SEVERAL ELECTRICAL ISSUES. STEREO SYSTEM - INTERMITTENT PROBLEMS WITH THE PRESETS RESETTING AND THE CLOCK SETTING BACK TO 12:00. ALSO THE VOLUME FLUCTUATING UP AND DOWN ON ITS OWN WHEN USING THE REAR CONTROLS. THE STEREO HAS BEEN REPLACED TWICE. STILL HAVING THE PROBLEM. REAR DRIVER SIDE …
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HAVE OWNED THIS 2006 FREESTAR SINCE NEW. SEVERAL ELECTRICAL ISSUES. STEREO SYSTEM - INTERMITTENT PROBLEMS WITH THE PRESETS RESETTING AND THE CLOCK SETTING BACK TO 12:00. ALSO THE VOLUME FLUCTUATING UP AND DOWN ON ITS OWN WHEN USING THE REAR CONTROLS. THE STEREO HAS BEEN REPLACED TWICE. STILL HAVING THE PROBLEM. REAR DRIVER SIDE TURN SIGNAL LAMP - HAS BURNED OUT AND BEEN REPLACED 7 TIMES. OUTSIDE TEMPERATURE PROBE - IS NOT READING PROPERLY. STARTER - HAVE INTERMITTENT PROBLEMS STARTING THE VEHICLE. HAVE NOT RECEIVED ANY RESOLUTION FROM SEVERAL DEALERS. THE PCM WAS NOT FOUND TO BE WET OR DAMAGED. ARE CONCERNED THAT THE VEHICLE HAS MAJOR WIRING ISSUES AND IS A POSSIBLE FIRE HAZARD. ALSO, THE REAR AC BLOWER SQUEALS INTERMITTENTLY AND HAS BEEN REPLACED TWICE AS WELL. STILL DOING IT. THERE IS A MUFFLED THUMP SOUND COMING FROM THE AIR CLEANER BOX AREA. THE LAST DEALER WHO LOOKED AT THE VEHICLE STATED THAT THIS IS NORMAL. WE DON'T AGREE. SEVERAL, UNRESOLVED, REPETITIVE ISSUES WITH THIS VEHICLE. VERY DISAPPOINTED WITH FORD AND WILL NOT PURCHASE ANOTHER. *TR
WHILE DRIVING ON THE INTERSTATE MY FORD FREE STAR CAUGHT FIRE UNDER THE HOOD. I WAS UNABLE TO OPEN THE HOOD AND PUT THE FIRE OUT. THE VAN TOTALLY BURNED.
WHILE DRIVING 45 MPH MY 2006 FORD FREESTAR (24,000 MI.) VAN COMPLETELY STALLED. THERE WERE NO WARNINGS AT ALL, IT JUST DIED. I SAFELY PULLED INTO A PARKING LOT AND PUSHED IT TO A SAFE LOCATION. I HAD IT TOWED TO A FORD DEALERSHIP. LATER IN THE DAY THEY STARTED IT RIGHT UP, CHECKED IT ALL OUT AND FOUND NOTHING WRONG. I WAS VE…
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WHILE DRIVING 45 MPH MY 2006 FORD FREESTAR (24,000 MI.) VAN COMPLETELY STALLED. THERE WERE NO WARNINGS AT ALL, IT JUST DIED. I SAFELY PULLED INTO A PARKING LOT AND PUSHED IT TO A SAFE LOCATION. I HAD IT TOWED TO A FORD DEALERSHIP. LATER IN THE DAY THEY STARTED IT RIGHT UP, CHECKED IT ALL OUT AND FOUND NOTHING WRONG. I WAS VERY LUCKY THAT NOBODY STOPPED IN FRONT OF ME OR I WOULD HAVE HIT THEM. I'M SCARED TO DRIVE IT NOW AFTER READING ALL THE COMPLAINS ONLINE ABOUT THIS HAPPENING TO OTHERS. THIS VAN HAS BEEN NOTHING BUT TROUBLE. *TR
Official recalls
213V081000 · Seats
Mar 7, 2013
Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. The third row stowable seat can experience corrosion and structural degradation at the seat anchor mechanism mounted to the rear wheel wells. As a result of the corrosion, the third row seat may not fully latch into its seating position.
Consequence & remedy
Consequence: In the event that the vehicle is crashed into from the rear, an unlatched seat may increase the risk of personal injury.
Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
06V069000 · Structure:body:hatchback/liftgate
Mar 9, 2006
ON CERTAIN VANS EQUIPPED WITH THE POWER LIFTGATE OPTION, THE POWER LIFTGATE MOTOR AUTOMATICALLY DISENGAGES AFTER THE LIFTGATE IS POWERED OPEN.
Consequence & remedy
Consequence: IN THE EVENT OF A LIFTGATE STRUT MALFUNCTION, THE LIFTGATE CAN FALL FREELY WITH NO PRIOR WARNING. ANYONE STANDING BENEATH THE LIFTGATE MAY BE INJURED IF THE LIFTGATE FALLS.
Remedy: DEALERS WILL REPROGRAM THE POWER LIFTGATE MODULE TO REDUCE THE LIKELIHOOD THAT THE LIFTGATE COULD FALL FREE OF CHARGE. THE RECALL BEGAN ON MARCH 15, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3EQ12010 · Stabilus Rear Liftgate Struts Failing
Opened Sep 28, 2012 · Closed Dec 31, 2012
Status: closed (inferred from source dates) · Structure:body:hatchback/liftgate:support Device/strut
Please see the attached closing resume summary.It has been attached to this document as a PDF.
EA12003 · Corrosion Of Third-Row Seat Attachment
Opened Apr 23, 2012 · Closed May 2, 2013
Status: closed (inferred from source dates) · Seats; Seats:mid/rear Assembly; Structure; Structure:body
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Additional source detail variants (4)
Seats
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Seats:mid/rear Assembly
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Structure:body
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
Structure
Ford is conducting a safety recall to repair the third-row seat's latch mechanisms in approximately 196,667 model year (MY) 2004 through 2007 Ford Freestar and Mercury Monterey vehicles (see NHTSA recall 13V-081 for more details).The recall covers vehicles originally sold, or currently registered, in the salt belt states or high corrosion areas of the United States: Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin.Approximately 100,000 remaining MY 2004-2007 Freestar and Monterey vehicles--those vehicles that were not originally sold, or are not currently registered, in salt belt states--are not included in the recall action. Although these vehicles are the same as the ones described above, they experience significantly lower failure rates because of reduced road salt exposure.ODI is currently aware of only one complaint on vehicle outside of the recall scope.ODI will monitor complaints and take further action if warranted by the circumstances.For owners of vehicles that are outside of the recall scope but exhibit the defect condition, owners (and affected Ford dealers) can contact Ford to request the recall repair.This Engineering Analysis is closed.See attached report and associated recall file for additional information.The ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10399896, 10410491, 10420028, 10424850, 10433928, 10436592, 10438529, 10440616, 10441489, 10441641, 10442809, 10446564, 10450295, 10450559, 10450587, 10452933, 10453826, 10454977, 10455545, 10456985, 10457423, 10457910, 10458738, 10459042, 10460511, 10461074, 10462910, 10463126, 10463262, 10463366, 10463600, 10464243, 10467003, 10467680, 10468429, 10469188, 10469200, 10470216, 10470510, 10471280, 10471520, 10471813, 10471978, 10472514, 10473087, 10473159, 10477025, 10477387, 10477954, 10478449, 10479247, 10479758, 10480611, 10480665, 10481054, 10481412, 10482213, 10482236, 10482613, 10482620, 10487872, 10489445, 10490515, 10490641, 10490663, 10490744, 10491495, 10492220, 10493470, 10493572, 10496348, 10497631, 10497976, 10498310, 10498433, 10499681, 10499861, 10500495.
PE10033 · Engine Stalling
Opened Aug 23, 2010 · Closed Jul 15, 2011
Status: closed (inferred from source dates) · Power Train:automatic Transmission:control Module (tcm/pcm/tecm); Vehicle Speed Control
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
Additional source detail variants (2)
Power Train:automatic Transmission:control Module (tcm/pcm/tecm)
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
Vehicle Speed Control
The subject vehicles suffered from a design issue whereby water could run down onto the cowling under the hood and located in the area of the windshield wipers and then drip onto a computer module, the Powertrain Control Module (PCM), which could be manifested in a variety of symptoms depending on which part of the circuit board became wet or which of the connector pins shorted out.In addition to causing an engine to stall, which may or may not then restart, the water intrusion could also cause the transmission to shift poorly, the vehicle to have erratic power, a malfunction indicator light to come on, or result in an inability to start the vehicle, an inability to shift the vehicle into either forward or reverse. Also the problem could cause a higher than normal idle RPM in Park, or for the radio to malfunction, or the interior lights to stay on.During this investigation ODI was concerned with the effect of the engine stalling or a drastic and sudden loss of power either of which may create a safety risk.In reviewing the actual number of these types of incidents, collectively referred to here as engine stalls, the number was found to be below what would be considered a defect trend.For example, the number of engine stalls identified in Ford's warranty claims for the model year (MY) 2004 subject vehicles, the MY with the most failures, was 200 out of population of 125,865, for a failure rate of 0.16%.The one crash recorded by a complainant to NHTSA, VOQ 10311522, alleged that the engine stalled, due to water intrusion into the PCM, while the road was turning causing her to go off the road and according to the police report the vehicle then hit an embankment and a tree stump. Ford reported in their response that there were three alleged crashes but none of these were validated as being caused by a problem with water intrusion into the PCM causing a stall.Accordingly this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.