Three problems related to frame rust have been reported for the 2005 Ford Freestyle. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Ford Freestyle based on all problems reported for the 2005 Freestyle.
During safety inspection, front engine subframe rusted beyond repair where steering gear is attached. Dick masheter Ford in columbus ohio provided diagnosis when performing other repairs. Replacement frame is unavailable from Ford directly; the only alternatives are getting a used subframe or having a new piece of steel welded in. Vehicle was stationary at the time of inspection.
The contact owns a 2005 Ford Freestyle. The contact took the vehicle in for a state safety inspection and the inspector noticed that the subframe was rusted. The inspector stated that the vehicle was unsafe to drive. The contact mentioned that two or three years before, rust was discovered during another state safety inspection. The vehicle was taken to an independent mechanic who performed welding work to the subframe. The vehicle was not taken to a dealer for diagnostic testing or repairs. Prime Ford saco (857 portland rd, saco, me 04072 (207) 282-0300) stated that there were no recalls for the rust failure. Since the vehicle was out of warranty, the dealer offered no further assistance. The manufacturer was not notified of the failure. The failure mileage was approximately 52,000. The VIN was unavailable.
2005 Ford Freestyle sel fwd - 116k miles, very good condition, 2nd owner. On 11/1, I requested mechanic to do a full inspection on the car, no know issues, but just to check it over before winter. Upon inspection, mechanic found the engine cradle subframe to be rusted/rotted beyond repair, and said car was not safe to drive. Only this cradle showed significant rust, in fact the original exhaust system is still on the car (that is most shocking, the exhaust out lasted this subframe). As I stated the car is in fantastic shape, and runs great. We either had to fix or scrap the car as it was unsafe to drive. Estimates from dealers to replace were around $3000. We ended up using a local body shop we trust to replace the subframe with a used / rust free one for $1150. I retained the subframe and called Ford customer service also to issue a complaint. I realize the car is 10 years old with over 100k miles on it, but given its great condition (if you saw pictures you would understand) there is no acceptable reason for a subframe, that holds all the suspension and steering to be rusted/rotted to the point of being unsafe to drive.