Ten problems related to brake disc caliper have been reported for the 2004 Ford Freestar. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford Freestar based on all problems reported for the 2004 Freestar.
The brake proportioning system (front/rear) does not function properly causing premature failure of the rear brakes. This allows the calipers to overextend and freeze causing rear brake failure and hydraulic fluid loss. This requires the replacement of the rear calipers every 15k miles this has occurred several times at approximately 15k intervals. This is the reverse of most vehicles that do the majority of their stopping with the front brakes.
I've been asking about the weird brake noise (grinding) each time I've taken my vehicle in for service at Ford dealerships. I was always told nothing was wrong and that my pads were fine. I took car to another repair shop because my brakes were obviously shot and they said the calipers were bad. They also said it seemed premature for my car. The Ford dealership said the same thing to me over the phone and a third repair shop said they shouldn't have been bad in the 2 years that I've owned the car. I've searched the web and found many others complaining of the same problem.
On 4/11/07 Ford service department. Informed me the rear brakes & rotors on the 04 Freestar were shot and needed immediate replacement at a cost of $575. 00. I thought they were lying to me because I had more than 20 different cars,trucks,& vans, but never had factory installed brake pads wear out at 20000 miles ,and especially rotor damage so bad that they had to be replaced. Also there was no warning signs like a grinding noise or a pulsating brake pedal. Nothing. So I mentioned the 3/36 bumper 2 bumper warranty ,and the 6/75000 esp plus deluxe extended warranty w/$0 deductible , and I was told this was a wear item , and was not covered. They said I probably rode the brake pedal or drove with the parking brake on. I didn't drive with 2 feet and never used the parking brake. I asked how long were the brakes designed to last under normal use, . They didn't know. So I left the dealer, and went to an independant ex Ford mechanic , who determined to find a frozen caliper or something else defective. What we found was not what I was expecting. The calipers were not frozen, and the pads were not completely worn down although the outer pads were twice as worn as the inner pads,there was no metal to metal contact(rivets or pad backing). It seems that the metallic or semi-metallic pads themselves would rust a bit and since the front brakes do most of the stopping,t he rust on the rear pads never completely wore off each day and the pads and rotors never heated up enough to built up the glaze like the front pads. So the rotors were gouged by the rust build up on the pads. When examined closely,the deep gouges on the rotors lined up with the rust build up on the pads.
The contact owns a 2004 Ford Freestar. While driving speeds ranging from 50 to 60mph, there is a grinding noise and the brake pedal is extended to the floorboard when depressed. The dealer stated that the rear calipers needed to be replaced. The vehicle was repaired. Approximately one week later she experienced the same failure. The contact stated that the problem has occurred on 4 occasions and it is worse when it is raining. The current and failure mileage were 9,558. The consumer has provided a copy of repair invoice. Updated 06/07/07.
The contact owns a 2004 Ford Freestar. While driving at 5 mph the contact heard a grinding noise in the rear of the vehicle when ever the brake were depressed. The mechanic stated that the grinding noise was due to the rear brakes. The mechanic replaced the rear brake pads, rotors, and calipers. There have not been any occurrences since the repair. The failure and current mileage was 40,000. Updated 05/04/07.
Faulty caliper on the Ford 2004 Freestar.
A rear brake caliper stuck which caused the brake pad to grind down to zero pad and into my rotor. I had to have the pads and rotors replaced due to the failure of the caliper. The caliper is a covered part under the warranty. The dealer and Ford refuses to cover the resulting damage to the rotors even though the warranty clearly states that it would do so. I want reimbursed for my repair.
On July 6 2005 the consumer took the vehicle in for inspection and while inspecting it, the dealer stated that there was a problem. The dealer reported the brake pads and rotors needed to replaced . The consumer thinks this is unfair because this car was inspected and checked regularly. There were no warnings from the vehicle that there was a problem. The consumer stated it was the caliper that originally caused the problem. Vehicle has not been repaired yet.
Grinding noise in rear pass side wheel. Caliper failed, caused the pad to slip and ate through the rotor causing the wheel to lock up completely. Took vehicle to Ford dealer, they advised the whole brake system needed to be replaced, which we did. Caliper, rotor, and pad replaced on rear pass side brake system, and pad replaced on rear driver's side.
Right rear brake caliper frozen after just one year.