One problem related to emission control has 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.
I bought a 2005 Ford Freestar used with 25000 miles on it. Three weeks later the gas cap light came on a day after that the check engine light came on, when the van was looked at the charcoal canister was cracked in the front. I was told something hit it and it was not under warranty. He showed it to me and other than the hole in the front there was no sign of any damage not a scratch. I called Ford and they told me they would not do any thing to help. My point to them was if something can hit the canister and crack it but not even scratch the paint on the underside of the van than it must be in a bad place. I can not replace it every three weeks at $500 a time. The old part will be available when I can replace the old one I do have pictures of it in place.