Four problems related to brake master cylinder 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.
In 2010 for no reason the traction control light was coming on. After 2 visits to the dealer they replaced the abs module and switch on the master cylinder. The problem seemed to be resolved but once in a while the light would come on. Now it is happening more frequently and the abs activates for no apparent reason (dry road and normal braking) which I consider a safety hazard.
12/06 front driver-side brake froze on while driving, causing van to want to pull into other lane. Dealer said faulty master cylinder. On 1/07 same thing happened on rear passenger side again causing van to pull. Different dealer says again a faulty master cylinder. Both incidents could have serious consequences. It seems more than coincidental. I feel this could be a potential design/recall problem.
: the contact stated the brake pedal went to the floor twice while attempting to stop. This occurred at 30 mph. The first time, there was no damage. The dealership was unable to determine a problem, but replaced the master cylinder. The second time, while approaching an intersection, the contact depressed the brake pedal. The vehicle did not slow down; the vehicle was steered to the right over a curb into a parking lot. The vehicle did not slow down and crossed a three lane highway into another parking lot where the vehicle was stopped by shrubs. This caused a tire to blow out and minor damage to the bumper. The vehicle was towed to the dealership, but the dealership was unable to determine a problem.
October 2004 - less than 500 miles on van - brakes went out. Tracklight came on. Van was towed to dealer and they replaced sensor on it. Rakes have gone out again - carried back to same dealership and they could not duplicate problem. Brakes would go down, afraid would not stop, and would finally catch after pumping repeatedly. Problem still occurring March 2005 - carried van to a different dealership. Master cylinder was leaking and was replaced. Brakes gone out again. Carried to dealership April 1, 2005 to leave and check. They drove van all weekend as personal vehicle (without permission), put 500 miles on vehicle but could not duplicate problem.