Four problems related to gas recirculation valve (egr valve) 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.
2004 Ford Freestar ses I changed the rear brakes on 1/20/2013 noticed the left rear wheel was rusting out. Today 2/24/2013 went to install a car sear & noticed the bench seat in the back was rocking slightly. The anchor point on the left rear is rusted out and moving. Upon inspection I noticed that I can see down to the ground where the anchor point has rusted out. I have had to replace numerous parts on this van over the last two years. To date I have replaced: 3 ignition coils, (this is the main problem whenever heavy rain or snow has happened and I start to throw misfire codes), 3 camshaft position sensors, 2 driver side window controls & motors, (the window doesn't want to work half the time so we leave it cracked open with the rain guards), an egr valve, and a clockspring. I have never had so many problems with this vehicle in such a short amount of time.
At 147000 miles, I needed a complete transmission rebuild. This cost me $2800 due to the fact that there were additional parts not common to a standard rebuild. This was sept. 2011. In January, I am able to note online that there is a torque converter recall for this model. I call Ford, I'm told there is nothing they can do until the recall is officially released in the 2nd quarter. Wait until 2nd quarter, no notice in the mail. I call Ford in August and tell them this, I am told that Ford will fix the car, it will take approx. 4 days and that no rental car is available during this period. If I suffer a total loss, maybe. Basically, I have to be stranded on the side of the road with my two young children before I can get any help with their issue. After rebuild, I start having issues with cylinder 3 misfire. I replace all plugs and wires, still a cylinder 3 misfire as well as overheating and egr valve. Replace egr valve, complete radiator change, coil pack, still issues with misfiring and overheating. I understand that this could be a computer issue, however Ford fails to realize this and therefore will not issue a recall. Not that that would help since if they took it into the shop to fix it, I would not be able to get to work in the interim.
Many issues with the van & they continue. Purchased from 1 previous owner, Jan '09 around 60k may 2010, 74k miles- replaced spark plugs & wires, fuel system cleaner: rough idle $432. 23 Dec 2010, 83k miles - replaced front axle & sway bar links: $822. 89 April 2011, ? miles, - replaced plugs & wires, coil pack: rough idle $700. 85 Jan 2012, 100k miles - replaced pvc evap hose, r&r fuel filter, fuel injector cleaner: rough idle $228. 40 Aug 15 2012, 106k miles - recall, torque converter replaced: costing me $162. 14 to replace seals & transmission filter Aug 16 2012, 106k miles - replaced egr valve: rough idle & engine light on after recall fix $135. 95 (dealership was kind enough to only charge for labor) Aug 31, 2012, 107k miles - engine is still running rough, piercing noise while driving, sometimes it goes away when I am turning.
2004 Ford Freestar. Consumer states vehicles drives rough, stating vehicle accelerates and decelerates on its own the consumer stated the vehicle would slow down and then speed up with rapid jerking. The consumer had the egr replaced at a cost of $289. 97. Also, the air conditioner compressor, ignition coil and main computer had to be replaced.