Two problems related to brake disc rotor have been reported for the 2005 Ford Freestar. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Ford Freestar based on all problems reported for the 2005 Freestar.
At approximately 28,000 miles we heard a terrible squealing noise coming from the rear of our 2005 Ford Freestar minivan and after visual inspection the brake pad on the driver's rear was worn to nothing. Immediately took the van to the dealer where they informed us that it was normal wear and would not be covered by our warranty. Upon further inspection by our personal mechanic we were informed the caliper was sticking and cut into the rotor. He put a set of brake pads on so we could drive it back to the dealer where we bought the vehicle, sunset Ford, in gravois. We were told since we did not use motocraft the repairs would not be covered. Now at 50,000 miles the problem still exists and the van needs another set of brakes and rotors.
Dt: about 2 weeks ago the brakes failed. When pressure was applied to the brake pedal it simply went all the way to the floor. It did slow down but as driver progressed the brake shoe hung to the rotor and made a clicking sound as though they were still applied. Afterwards consumer contacted dealership and took vehicle in. The technician stated it was a rotor problem. The dealer grinded rust or " lot rot" off the rotors and placed them back on the vehicle. Two days ago however the same incident occurred again with the brake pads sticking to the rotor and the clicking noise. The vehicle is back at the dealer who says they can not find anything wrong with it. The consumer has not contacted manufacturer.