Two problems related to brake grinding noise 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.
I purchased a 2004 Ford Freestar. Within 1 year after purchase, I heard grinding noises from the rear brakes. The brakes would also "squeal" while I was driving down the road. In 2007, I had the rear rotors replaced by a dealship because of gouging and pitting that they felt was not normal wear and tear. I had 29,600 miles on the vehicle at the time. Now, from the day I drove it home from being repaired, I would have the same squealing and grinding noises. I took the van in to have the brakes inspected again and was told that the rotors or extremely ground down due to excessive pitting and gouging. I now have 50,000 miles on the vehicle and only 20,000 miles on these rotors. The dealership would not replace them at no charge because they are not under warranty and said that this is due to normal wear and tear. I should not have to replace the rear brakes every 20,000 miles or so. I have followed up with Ford corporate and they refuse to acknowledge that this is a problem or to do anything about it.
The vehicle I own is a 2004 Ford Freestar van. I purchased in 2003. It has 35,698 miles on it. At approximately 35,000 miles the rear brakes started making a grinding noise when the brakes were applied. I took it to the dealer where it was purchased- the brakes had to be replaced-including rotors and pads. Thg rotors were so worn there was no way to turn them-they had to be replaced. A total cost of $447. Why did these brakes wear out so severely with only 34,00 miles on them? and why not the front brakes-this was on the rear brakes! I've never had a brake job on it so far- until this!.