Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
STRUCTURE - BODY - DOOR
0422911/15/200410013404Access door wraped or breaking off from the underside of the steering wheel shrod. *eh04/18/2005
0218402/09/2004042310007365Power sliding door operation and diagnostic service tips. *tt06/16/2004
1567908/01/200417971636308Sliding door(s) contacting the rear quarter glass. *tt this information updates previous information, dated 03/01/2002. *tt11/07/2002

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
STRUCTURE
PE11039FORD MOTOR COMPANY12/21/201104/27/2012Corrosion of Third-Row Seat Attachment
 Odi has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.additionally, odi identified 4 similar reports from ford's response to the investigation.ford submitted a total of 10 reports to odi (6 of 10 ford reports are duplicates of odi reports).the complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).the first report of this condition was received in march 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.odi seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.in addition to the subject vehicles, odi also will collect and review information on my 2005-2007 freestar/monterey vehicles that appear to have a seat design identical to the subject vehicles.to date, odi is not aware of any similar complaints on the my 2005-2007 vehicles.odi also will collect and review information on freestar/monterey vehicles used outside of the salt belt states.this preliminary evaluation has been upgraded to an engineering analysis (ea12-003) to further assess whether a safety defect exists in the subject vehicles.the odi reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/complaints under the following identification (odi) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
EA12003FORD MOTOR COMPANY04/23/2012Corrosion of Third-Row Seat Attachment
 Odi has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells. additionally, odi identified 4 similar reports from ford's response to the investigation.ford submitted a total of 10 reports to odi (6 of 10 ford reports are duplicates of odi reports).the complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well). the first report of this condition was received in march 2011 and subsequent reporting frequency indicates a potentially increasing trend over timeodi seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.in addition to the subject vehicles, odi also will collect and review information on my 2005-2007 freestar/monterey vehicles that appear to have a seat design identical to the subject vehicles.to date, odi is not aware of any similar complaints on the my 2005-2007 vehicles.odi also will collect and review information on freestar/monterey vehicles used outside of the salt belt states.an engineering analysis has been opened to further assess whether a safety defect exists in the subject vehicles.the odi reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/complaints under the following identification (odi) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
PE11039FORD MOTOR COMPANY12/21/2011Corrosion of the Third-Row Seat Mounting
 The stowable third-row seat is secured to the vehicle by two latches or anchors on each side of the seat cushion and also by two hinges/supports on the rear face of the seat cushion.the side anchors are mounted to the rear wheel wells.odi has received seven complaints on model year 2004 ford freestar and mercury monterey vehicles which were in use in salt-belt states.the complaints allege that the rear wheel wells were severely corroded with some complaints indicating that an anchor mount completely detached from the vehicle.an investigation has been opened to assess the alleged defect in the subject vehicles.
STRUCTURE - BODY
PE11039FORD MOTOR COMPANY12/21/201104/27/2012Corrosion of Third-Row Seat Attachment
 Odi has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells.additionally, odi identified 4 similar reports from ford's response to the investigation.ford submitted a total of 10 reports to odi (6 of 10 ford reports are duplicates of odi reports).the complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well).the first report of this condition was received in march 2011 and subsequent reporting frequency indicates a potentially increasing trend over time.odi seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.in addition to the subject vehicles, odi also will collect and review information on my 2005-2007 freestar/monterey vehicles that appear to have a seat design identical to the subject vehicles.to date, odi is not aware of any similar complaints on the my 2005-2007 vehicles.odi also will collect and review information on freestar/monterey vehicles used outside of the salt belt states.this preliminary evaluation has been upgraded to an engineering analysis (ea12-003) to further assess whether a safety defect exists in the subject vehicles.the odi reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/complaints under the following identification (odi) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
EA12003FORD MOTOR COMPANY04/23/2012Corrosion of Third-Row Seat Attachment
 Odi has received 18 complaints on the subject vehicles from the salt belt states that allege severe corrosion at the rear wheel wells. additionally, odi identified 4 similar reports from ford's response to the investigation.ford submitted a total of 10 reports to odi (6 of 10 ford reports are duplicates of odi reports).the complaints indicated difficulty or inability to latch the rear seat as some of the complaints reported the entire anchor plate completely detached from the vehicle (rear wheel well). the first report of this condition was received in march 2011 and subsequent reporting frequency indicates a potentially increasing trend over timeodi seeks to evaluate the potential occupant safety risks resulting from structurally degraded seat anchorages.in addition to the subject vehicles, odi also will collect and review information on my 2005-2007 freestar/monterey vehicles that appear to have a seat design identical to the subject vehicles.to date, odi is not aware of any similar complaints on the my 2005-2007 vehicles.odi also will collect and review information on freestar/monterey vehicles used outside of the salt belt states.an engineering analysis has been opened to further assess whether a safety defect exists in the subject vehicles.the odi reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/complaints under the following identification (odi) numbers: 10454977, 10453826, 10452933, 10450587, 10450559, 10450295, 10446564, 10442809, 10441641, 10441489, 10440616, 10438529, 10436592, 10433928, 10424850, 10420028, 10410491 and 10399896.
PE11039FORD MOTOR COMPANY12/21/2011Corrosion of the Third-Row Seat Mounting
 The stowable third-row seat is secured to the vehicle by two latches or anchors on each side of the seat cushion and also by two hinges/supports on the rear face of the seat cushion.the side anchors are mounted to the rear wheel wells.odi has received seven complaints on model year 2004 ford freestar and mercury monterey vehicles which were in use in salt-belt states.the complaints allege that the rear wheel wells were severely corroded with some complaints indicating that an anchor mount completely detached from the vehicle.an investigation has been opened to assess the alleged defect in the subject vehicles.
STRUCTURE - BODY - HATCHBACK/LIFTGATE - SUPPORT DEVICE
EQ12010Ford Motor Company09/28/201212/31/2012Stabilus Rear Liftgate Struts Failing
 Please see the attached closing resume summary.it has been attached to this document as a pdf.
EQ12010Ford Motor Company09/28/2012Stabilus Rear Liftgate Struts Failing
 On february 16, 2012, american honda motor company (honda) notified the nhtsa that it had decided a defect exists in certain model year 2008 through 2009 odyssey vehicles.gas-filled struts that help to raise and support the liftgate of vehicles equipped with a power liftgate system may be prone to early life failures due to a manufacturing flaw.the flaw can result in a leak of the pressurized gas, leading to reduced strut performance.struts with diminished performance can lead to unexpected closure, increasing the risk of personal injury.stabilus was identified as the manufacturer of these gas-filled strutsthis matter was assigned recall number 12v-062.in reviewing past records, rmd discovered similar recalls conducted by toyota, ford, and honda between 2006 and 2010.on february 18, 2010, honda notified the nhtsa of the same rear liftgate gas strut issue in its 2005 odyssey vehicles.this issue was given recall number 10v-055.on may 30, 2008, toyota motor corporation (toyota) notified the nhtsa of the same issue found in its 2004 through 2006 sienna vehicles.this issue was given recall number 08v-244.on march 6, 2006, ford motor company (ford) notified the nhtsa of the same issue found in its 2005 through 2006 freestar and mercury monterey vehicles.this issue was given recall number 06v-069.these three recalls did not originally identify the supplier of the gas struts, however, all three manufacturers have since confirmed that stabilus supplied the equipment at issue in each recall.the purpose of the eq is to write to stabilus and to contact any other company that might have purchased this equipment, notify them of this defect in any vehicles they manufactured, and to ensure thorough safety recalls are conducted where appropriate.

Consumer Complaints


Fail datemilesoccurencesPurchase date
STRUCTURE
09/29/2012870001
 I am entering this complaint in relation to other complaints that have been filed. there is a defect investigation taking place (ea12003 and pe11039) for this issue already. i attempted to put my 3rd row seat back up and lock it into place. on the drive side i noticed that it would not lock into place. after further review, i know noticed that the whole latch had fallen off and was laying on the back driver side wheel. the whole plate rusted thru and fell off into the wheel well. i've had this car since 2004. yes i live in a snow state that uses salt, but this car has been in the garage its entire life. i would like to understand what stance, if any, ford is taking with this issue. *tr
07/17/201197500
 Tl- the contact owns a 2004 ford freestar. the contact stated that the side panel that held the back seat bracket was corroded. the vehicle was taken to the dealer who verified the failure and stated that the panel needed to be replaced. the manufacturer was made aware of the failure who did not offer any assistance. the vehicle was not repaired. the failure mileage was 97,500 and the current mileage was 98,600. kmj
07/17/201197500
 Tl - the contact owns a 2004 ford freestar. the contact stated that the side panel that hold the back seat bracket was corroded. the vehicle was taken to the dealer who verified the failure and stated that the panel needed to be replace. the manufacturer was made aware of the failure who did not offered any assistance. the vehicle was not repaired. the failure mileage was 97,500 and the current mileage was 98,600. pm
04/30/20111
 Ltr on behalf of concern the safety of her 2004 ford freestar re the rusting of the 3rd row seats anchoring latch system; reply attn kay rash/davenport district office *tgw the consumer was informed it was not cost effective to fix the vehicle. *jb
04/30/2011113000
 Tl* the contact owns a 2004 ford freestar. the contact stated while attempting to latch the third row rear seat, the latch failed due to severe corrosion on the floor panel and attachments. the vehicle was taken to the dealer who inspected the vehicle and advised that the vehicle was unsafe to be driven. the vehicle was not repaired. the vin was not available. the failure and current mileage was 113,000.
04/30/2011113000
 Tl-the contact owns a 2004 ford freestar. the contact stated while attempting to latch the third row rear seat the latch failed due to severe corrosion on the floor panel and attachments. the vehicle was taken to the dealer inspected the vehicle, and advised the vehicle was unsafe to be driven. the vehicle has not been repaired. the vin information was not available. the failure and the current miles was 113,000. li
04/06/20091
 2004 ford freestar. s10 appropriate handling - letter to the president from nadine burroughs re vehicle hazards due to major defects (full document not imaged). *nj the check engine light illuminated. the codes were for a cmp sensor and ac pressure sensor. the powertrain control module needed to be replaced due to water intrusion. the vehicle would stall while on the highway. the consumer stated there were no problems with the vehicle until a water leak happened. *jb
03/01/20071
 2004 ford freestar, back liftgate. a design flaw allows rainwater or water from a car washing) to seep in, accumulate, and puddle all around the latch mechanism of the back lift gate. this causes it to freeze on icy days which causes difficulty opening or closing the back liftgate. eventually, the latch mechanism rusts out completely and has to be replaced. this is an obvious design flaw. *tr
01/08/200844000510/08/2005
 Van without warning stopped moving and engine cut off. this is a follow up from our christmas adventure. got it towed to dealer and after 2 days of looking into the problem told me that water leaked in from under dash(it had not rained or snowed for days- roads weren't even wet) and got the computer wet an caused it to malfunction. sealed leak and $250 later sent us on our way. fast forward 2weeks and our van is back in the shop again for the same problems. come on now, enough is enough!!!!! recall this problem before people get killed!!!!! *tr
STRUCTURE - BODY
01/20/20131540001
 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. *tr
01/20/2013154000
 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.
02/20/201322500
 Severe rust issues plague the frame, jack points, and rear frame (spare tire storage area). the spare tire wheel looks as if it has never had paint on it there is so much rust. we just purchased the vehicle a few days ago and are currently working with the ford dealer to hopefully get the problem corrected. we did not realize the severe rust issues prior to purchase.
01/20/2013154000
 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.
02/20/201322500
 Severe rust issues plague the frame, jack points, and rear frame (spare tire storage area). the spare tire wheel looks as if it has never had paint on it there is so much rust. we just purchased the vehicle a few days ago and are currently working with the ford dealer to hopefully get the problem corrected. we did not realize the severe rust issues prior to purchase.
01/20/2013154000
 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.
02/20/201322500
 Severe rust issues plague the frame, jack points, and rear frame (spare tire storage area). the spare tire wheel looks as if it has never had paint on it there is so much rust. we just purchased the vehicle a few days ago and are currently working with the ford dealer to hopefully get the problem corrected. we did not realize the severe rust issues prior to purchase.
02/15/20131600001
 As stated with other 2004 ford freestars, rear rust on driverside rear, rear seat will not lock because the safety lock is rusted away, not safe to any passenger to sit there. *tr
02/15/2013160000
 As stated with other 2004 ford freestars, rear rust on driverside rear, rear seat will not lock because the safety lock is rusted away, not safe to any passenger to sit there
01/28/2013140000
 Tl* the contact owns a 2004 freestar. the contact stated that while driving approximately 25 mph, a loud grinding sound was heard coming from the rear tires. the contact also stated that the wheel mount and wheel well were rusted. in addition, the third row latch failed and the seats were unable to stay folded. the vehicle was taken to the dealer for diagnostics. the technician stated that the wheel well and latches needed to be replaced. the manufacturer was made aware of the failure but did not offer any further assistance due to the vehicle not being included in any recalls. the vehicle was not repaired. the approximate failure mileage and current mileage was 140,000.
01/28/2013140000
 Tl- the contact owns a 2004 freestar. the contact stated that while driving approximately 25 mph, a loud grinding sound was heard coming from the rear tires. the contact also stated that the wheel mount and wheel well were rusted. in addition, the third row latch failed and the seats were unable to stay folded. the vehicle was taken to the dealer for diagnostics. the technician stated that the wheel well and latches needed to be replaced. the manufacturer was made aware of the failure but did not offer any further assistance due to the vehicle not being included in any recalls. the vehicle was not repaired. the approximate failure mileage and current mileage was 140,000. mah
01/28/2013140000
 Tl - the contact owns a 2004 ford freestar. the contact stated that while driving approximately 25 mph, a loud grinding sound was heard coming from the rear tires and notice the wall mount was rusted. also the contact mentioned the wheel well and latched fell out causing the third seat not to be able to latch down. the vehicle was taken to the dealership for a diagnostic testing. the technician stated the wheel well and latches needed to be replaced. the manufacturer was made aware of the failure but did not offer any further assistance due to the vehicle not being included in any recalls. the vehicle was not repaired. the approximate failure mileage and current mileage was 140,000. dr
01/11/20131600001
 Back seat wouldn't latch. found rotten wheel well due to rust and corrosion and latch fell out along with a piece of the wheel well. now, there is a hole where the latch was and the rear seat is unsafe due to the fact that there is no latch to hold it in place. i have three kids so now their life is in jeopardy and the van isn't even 10 years old. we've had so many issues with this van. also, the computer had to be replaced due to water damage. we were told chevy had the same problem of water coming right down onto the computer and they designed a part for it, but not ford. *tr
01/18/20131008001
 The left rear 3rd row seat anchor plate, mounted normally to the left rear inner wheelhouse as an integrated part of the wheelhouse, has rusted around the plate edges and the entire plate is separating from the wheelhouse assembly. currently it is rusted thru on the left , right, and bottom edges of the mounting plate, remaining attached only along its top edge. this is letting road moisture into the interior regions of the van, soiling carpet and jute, causing odor and possible mold development. the 3rd row seat can no longer be safely attached. *tr
01/11/2013160000
 Back seat wouldn't latch. found rotten wheel well due to rust and corrosion and latch fell out along with a piece of the wheel well. now, there is a hole where the latch was and the rear seat is unsafe due to the fact that there is no latch to hold it in place. i have three kids so now their life is in jeopardy and the van isn't even 10 years old. we've had so many issues with this van. also, the computer had to be replaced due to water damage. we were told chevy had the same problem of water coming right down onto the computer and they designed a part for it, but not ford.
01/18/20131008001
 The left rear 3rd row seat anchor plate, mounted normally to the left rear inner wheelhouse as an integrated part of the wheelhouse, has rusted around the plate edges and the entire plate is separating from the wheelhouse assembly. currently it is rusted thru on the left , right, and bottom edges of the mounting plate, remaining attached only along its top edge. this is letting road moisture into the interior regions of the van, soiling carpet and jute, causing odor and possible mold development. the 3rd row seat can no longer be safely attached. *tr
01/18/2013100800
 The left rear 3rd row seat anchor plate, mounted normally to the left rear inner wheelhouse as an integrated part of the wheelhouse, has rusted around the plate edges and the entire plate is separating from the wheelhouse assembly. currently it is rusted thru on the left , right, and bottom edges of the mounting plate, remaining attached only along its top edge. this is letting road moisture into the interior regions of the van, soiling carpet and jute, causing odor and possible mold development. the 3rd row seat can no longer be safely attached.
01/11/2013160000
 Back seat wouldn't latch. found rotten wheel well due to rust and corrosion and latch fell out along with a piece of the wheel well. now, there is a hole where the latch was and the rear seat is unsafe due to the fact that there is no latch to hold it in place. i have three kids so now their life is in jeopardy and the van isn't even 10 years old. we've had so many issues with this van. also, the computer had to be replaced due to water damage. we were told chevy had the same problem of water coming right down onto the computer and they designed a part for it, but not ford.
01/18/2013100800
 The left rear 3rd row seat anchor plate, mounted normally to the left rear inner wheelhouse as an integrated part of the wheelhouse, has rusted around the plate edges and the entire plate is separating from the wheelhouse assembly. currently it is rusted thru on the left , right, and bottom edges of the mounting plate, remaining attached only along its top edge. this is letting road moisture into the interior regions of the van, soiling carpet and jute, causing odor and possible mold development. the 3rd row seat can no longer be safely attached.
12/12/2012997501
 I own 2004 ford freestar. while attempting to latch the third row rear seat, the latch failed due to severe corrosion on the floor panel ,side panel and attachments which holds the third seat latch bracket the third row seat latch bracket slides out and extrudes to rear driver side wheel which is very dangerous and can burst the rear driver side tire while running car. i am entering this complaint in relation to other complaints that have been filed. there is a defect investigation taking place (ea12003 and pe11039) for this issue already. i attempted to put my 3rd row seat back up and lock it into place. on the drive side i noticed that it would not lock into place. after further review, i know noticed that the whole latch had broken off because of rusted panel. the whole plate rusted thru . *tr
12/12/201299750
 I own 2004 ford freestar. while attempting to latch the third row rear seat, the latch failed due to severe corrosion on the floor panel ,side panel and attachments which holds the third seat latch bracket the third row seat latch bracket slides out and extrudes to rear driver side wheel which is very dangerous and can burst the rear driver side tire while running car. i am entering this complaint in relation to other complaints that have been filed. there is a defect investigation taking place (ea12003 and pe11039) for this issue already. i attempted to put my 3rd row seat back up and lock it into place. on the drive side i noticed that it would not lock into place. after further review, i know noticed that the whole latch had broken off because of rusted panel. the whole plate rusted thru .
11/10/20121120001
 During sts tire servicing, mechanic showed me a large section of structural steel hanging from the rear driver side wheel well and a michelin tire that contained abrasive ripping caused by the section of steel that had been dangling and rubbing against the tire. the large section of steel contained an anchor at the center which was manufactured to hold the third row row in place. this steel plate with the anchor for holding the third row seat in place is no longer attached to the vehicle due to a manufacturing defect which allowed the welds holding it in place to fail creating dangers of: unsecured seating, hole exposing passengers to exterior of vehicle and moving parts, opening for rodents or other dangers to enter vehicle, knowledge of prior may cause fear and panic of driver or passengers which may cause accident or mental anguise. i brought the vehicle to smith ford dealership in washington, n.j. requesting an inspection and warranty repair of the above stated structural steel. smith ford inspected the vehicle and said that the manufacturing defect would not be repaired by ford and that ford does not accept financial responsibility even though the problem was the result of a manufacturing defect. reported this to ford headquarters on november 30, 2012 and was informed that the dealership was correct in stating that ford will not repair this serious problem. my wife is increasingly having terrifying visions of mice jumping on her while driving, having snakes crawling into the car, rain snow mud etc entering vehicle, or having the children put their hands or other things into the hole in the vehicle. *tr
11/10/2012112000
 During sts tire servicing, mechanic showed me a large section of structural steel hanging from the rear driver side wheel well and a michelin tire that contained abrasive ripping caused by the section of steel that had been dangling and rubbing against the tire. the large section of steel contained an anchor at the center which was manufactured to hold the third row row in place. this steel plate with the anchor for holding the third row seat in place is no longer attached to the vehicle due to a manufacturing defect which allowed the welds holding it in place to fail creating dangers of: unsecured seating, hole exposing passengers to exterior of vehicle and moving parts, opening for rodents or other dangers to enter vehicle, knowledge of prior may cause fear and panic of driver or passengers which may cause accident or mental anguise. i brought the vehicle to smith ford dealership in washington, n.j. requesting an inspection and warranty repair of the above stated structural steel. smith ford inspected the vehicle and said that the manufacturing defect would not be repaired by ford and that ford does not accept financial responsibility even though the problem was the result of a manufacturing defect. reported this to ford headquarters on november 30, 2012 and was informed that the dealership was correct in stating that ford will not repair this serious problem. my wife is increasingly having terrifying visions of mice jumping on her while driving, havings snakes crawling into the car, rain snow mud etc entering vehicle, or having the children put their hands or other things into the hole in the vehicle.
12/21/2012100000
 Tl-the contact owns a 2004 ford freestar. the contact stated there was a clicking sound coming from the rear of the vehicle. upon inspection from the driver rear side next to the wheel well was a huge square bolt that was corroded. this bolt was a bracket that snaps and held the rear seat in place and it was broken off. the seat was unable to latch and hold in place. neither the dealer nor the manufacturer was notified. the failure mileage was 100,000. mw
08/24/20121420001
 Drivers side rear passenger seat bracket failure. the bracket is mounted through the wheel well. the weld around the bracket had severe rusting, no where similar to other parts of the car. the plate holding the bracket rusted through completely dropping the seat. the plate and bracket began rubbing against the tire. if i had not stopped and found the problem and secured the bracket, the tire could have blown causing an accident. accident was prevented, but serious body failure occurred. this needs to be addressed. as is this seat should no longer be used until it can be fixed, there is no cost effective fix. *tr
08/24/2012142000
 Drivers side rear passenger seat bracket failure. the bracket is mounted through the weel well. the weld around the bracket had severe rusting, no where similar to other parts of the car. the plate holding the bracket rusted through completely dropping the seat. the plate and bracket began rubbing against the tire. if i had not stopped and found the problem and secured the bracket, the tire could have blown causing an accident. accident was prevented, but serious body failure occurred. this needs to be addressed. as is this seat should no longer be used until it can be fixed, there is no cost effective fix.
10/13/20121690001
 The 3rd row rear seat on my 2004 freestar does not latch into seated position properly. upon further inspection, i realized that the driver's side support ring which the 3rd row seat latches into was pushed back into the trim. i looked underneath the driver's side rear wheel well and noticed that a steel plate which the support ring is mounted has completely rusted through the body of the vehicle. also, when it is not latched it has a tendency to interfere with the rear driver's side tire. while there is a small amount of metal holding the mounting plate in place, it requires two people to latch the seat in order to keep the metal plate from scoring the sidewall of my tire. the passenger's side mounting plate continues to be secure, yet there is a noticeable amount of rust on that side as well. if someone stows the 3rd row seat and tries to flip it back into seating position without knowing that the support ring is loose, they could end up scoring the sidewall on the rear tire and causing a complete failure. further, the proper function of the seat belt in the third row seat could be compromised during an accident; the seat could pitch forward or flip back because it is not solidly secured to the van's structure. *tr
10/13/2012169000
 The 3rd row rear seat on my 2004 freestar does not latch into seated position properly. upon further inspection, i realized that the driver's side support ring which the 3rd row seat latches into was pushed back into the trim. i looked underneath the driver's side rear wheel well and noticed that a steel plate which the support ring is mounted has completely rusted through the body of the vehicle. also, when it is not latched it has a tendency to interfere with the rear driver's side tire. while there is a small amount of metal holding the mounting plate in place, it requires two people to latch the seat in order to keep the metal plate from scoring the sidewall of my tire. the passenger's side mounting plate continues to be secure, yet there is a noticeable amount of rust on that side as well. if someone stows the 3rd row seat and tries to flip it back into seating position without knowing that the support ring is loose, they could end up scoring the sidewall on the rear tire and causing a complete failure. further, the proper function of the seat belt in the third row seat could be compromised during an accident; the seat could pitch forward or flip back because it is not solidly secured to the van's structure.
06/12/2012143000
 Inability to latch the rear seat, entire driver side anchor plate completely detached from the vehicle,
10/10/20121538501
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occurring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped. *tr
06/12/2012143000
 Inability to latch the rear seat, entire driver side anchor plate completely detached from the vehicle,
10/10/20121538501
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occurring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped. *tr
06/12/2012143000
 Inability to latch the rear seat, entire driver side anchor plate completely detached from the vehicle,
10/10/2012153850
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occuring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped.
06/12/2012143000
 Inability to latch the rear seat, entire driver side anchor plate completely detached from the vehicle,
10/10/2012153850
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occuring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped.
06/12/2012143000
 Inability to latch the rear seat, entire driver side anchor plate completely detached from the vehicle,
10/10/2012153850
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occuring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped.
09/11/201290000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while parked the contact pulled the rear seats up and noticed the stud which holds the back seat in place was loose. the contact pushed the stud and it fractured. also, the wheel weld was corroded on the rear driver and passenger side. the vehicle was taken to the dealer who was unable to determine how to remedy the failure. the vehicle was later taken to an independent mechanic who welded new metal pieces to the wheel wells on the rear driver and passenger side. there was an investigation under nhtsa action number: ea12003 (seats:mid/rear assembly structure structure:body) that may be related to the failure. the vehicle was repaired. the approximate failure mileage was 90,000. pmb
10/10/2012153850
 The left rear seat anchor has detached from the body due to excessive rust in the rear quarter panel by the left rear wheel well. the third seat is no longer usable and there is a hole through the body that lets air and water into the passenger compartment. the right side wheel well area shows rust as well but the seat anchor has not yet detached from the quarter panel. two ford dealers have said they are not aware of this problem occuring and do not know if it can be fixed. my concern is safety while driving the vehicle, noise and water entering the passenger compartment, and the loss of use of the third seat. this vehicle is too young and useful to be scrapped.
09/11/201290000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while parked the contact pulled the rear seats up and noticed the stud which holds the back seat in place was loose. the contact pushed the stud and it fractured. also, the wheel weld was corroded on the rear driver and passenger side. the vehicle was taken to the dealer who was unable to determine how to remedy the failure. the vehicle was later taken to an independent mechanic who welded new metal pieces to the wheel wells on the rear driver and passenger side. there was an investigation under nhtsa action number: ea12003 (seats:mid/rear assembly structure structure:body) that may be related to the failure. the vehicle was repaired. the approximate failure mileage was 90,000. pmb
10/07/20121560001
 Our son was in the rear seat and complained that as we turned corners, his seat moved. he said it felts as if it were not latched. upon investigation, we found the seat did not latch on the drivers side. we tried without success to relatch it and found the latch anchor was loose. being dark and 30 miles from home, we drove on. we then heard loud noise coming from that wheel well and began to smell burning rubber. having no other option, we pulled to the side of the dark highway and saw a piece of metal hanging out of the van, onto the tire. we pulled it the rest of the way out and found that it was the seat latch anchor. the area seems to be completely rusted...from the inside. the metal did not look rusted from the outside. we now have a hole in the side of the van (in the wheel well) and a van which is incapable of hauling our family of five. even using it as a four-passenger van, we have concerns about exhaust entering the interior of the van. (mileage noted is approximate). *tr
09/11/201290000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while parked the contact pulled the rear seats up and noticed the stud which holds the back seat in place was loose. the contact pushed the stud and it fractured. also, the wheel weld was corroded on the rear driver and passenger side. the vehicle was taken to the dealer who was unable to determine how to remedy the failure. the vehicle was later taken to an independent mechanic who welded new metal pieces to the wheel wells on the rear driver and passenger side. there was an investigation under nhtsa action number: ea12003 (seats:mid/rear assembly structure structure:body) that may be related to the failure. the vehicle was repaired. the approximate failure mileage was 90,000. pmb
10/07/20121560001
 Our son was in the rear seat and complained that as we turned corners, his seat moved. he said it felts as if it were not latched. upon investigation, we found the seat did not latch on the drivers side. we tried without success to relatch it and found the latch anchor was loose. being dark and 30 miles from home, we drove on. we then heard loud noise coming from that wheel well and began to smell burning rubber. having no other option, we pulled to the side of the dark highway and saw a piece of metal hanging out of the van, onto the tire. we pulled it the rest of the way out and found that it was the seat latch anchor. the area seems to be completely rusted...from the inside. the metal did not look rusted from the outside. we now have a hole in the side of the van (in the wheel well) and a van which is incapable of hauling our family of five. even using it as a four-passenger van, we have concerns about exhaust entering the interior of the van. (mileage noted is approximate). *tr
09/11/201290000
 Tl- the contact owns a 2004 ford freestar. while parked the contact pulled the rear seats up and noticed the stud which holds the back seat in place was loose. the contact pushed the stud and it fractured. the wheel weld was corroded on the rear driver and passenger side. the vehicle was taken to the dealer for diagnostic testing. the technician stated the they had no repair for the failure. the vehicle was later taken to an independent mechanic. the mechanic stated he would weld new metal pieces to the wheel well on the rear driver and passenger side. there was an investigation under nhtsa action number: ea12003 (seats:mid/rear assembly structure structure:body) that may be related to the failure. the vehicle was repaired. the approximate failure mileage was 90,000. da
10/07/2012156000
 Our son was in the rear seat and complained that as we turned corners, his seat moved. he said it felts as if it were not latched. upon investigation, we found the seat did not latch on the drivers side. we tried without success to relatch it and found the latch anchor was loose. being dark and 30 miles from home, we drove on. we then heard loud noise coming from that wheel well and began to smell burning rubber. having no other option, we pulled to the side of the dark highway and saw a piece of metal hanging out of the van, onto the tire. we pulled it the rest of the way out and found that it was the seat latch anchor. the area seems to be completely rusted...from the inside. the metal did not look rusted from the outside. we now have a hole in the side of the van (in the wheel well) and a van which is incapable of hauling our family of five. even using it as a four-passenger van, we have concerns about exhaust entering the interior of the van. (mileage noted is approximate)
08/16/20121479651
 The third row seat was loose when locked in the upright position. when i looked underneath from the driver side rear tire i noticed the metal plate was loose. i put down the third row seat and looked through the plastic to see that all around the metal plate rotted away. since the third row seat was not locked in place when i touched the bracket on the metal plate, the entire plate fell out onto the rear tire. the metal all around the plate inside the rear quarter panel is rotted and there is nothing to weld the plate back to. there is also a large opening into the vehicle because that plate is no longer there. my seven seat van can only hold four people safely. *tr
08/16/2012147965
 The third row seat was loose when locked in the upright position. when i looked underneath from the driver side rear tire i noticed the metal plate was loose. i put down the third row seat and looked through the plastic to see that all around the metal plate rotted away. since the third row seat was not locked in place when i touched the bracket on the metal plate, the entire plate fell out onto the rear tire. the metal all around the plate inside the rear quarter panel is rotted and there is nothing to weld the plate back to. there is also a large opening into the vehicle because that plate is no longer there. my seven seat van can only hold four people safely.
09/23/201272938
 Severe rust in the driver side rear wheel well caused the third row seat to detach from the vehicle. the third row seat is now unsafe and cannot be used. the seat can no longer be securely latched in place. this vehicle was garage kept and only has 72,938 miles on it.
08/16/2012147965
 The third row seat was loose when locked in the upright position. when i looked underneath from the driver side rear tire i noticed the metal plate was loose. i put down the third row seat and looked through the plastic to see that all around the metal plate rotted away. since the third row seat was not locked in place when i touched the bracket on the metal plate, the entire plate fell out onto the rear tire. the metal all around the plate inside the rear quarter panel is rotted and there is nothing to weld the plate back to. there is also a large opening into the vehicle because that plate is no longer there. my seven seat van can only hold four people safely.
09/23/201272938
 Severe rust in the driver side rear wheel well caused the third row seat to detach from the vehicle. the third row seat is now unsafe and cannot be used. the seat can no longer be securely latched in place. this vehicle was garage kept and only has 72,938 miles on it.
08/08/201284000
 Tl* the contact owns a 2004 ford freestar. the contact stated that whenever she engaged the brake pedal, it felt hot to the touch. the contact stated that after inspecting the vehicle she noticed that there was a piece of metal rubbing against the tire. the vehicle was taken to the dealer who diagnose that the rear wheel well needed to be replaced. the vehicle was repaired. the manufacturer was made aware of the failure who did not offer any assistance. the failure mileage was 84,000.
08/08/201284000
 Tl- the contact owns a 2004 ford freestar. the contact stated that whenever she engaged the brake pedal, it felt hot to the touch. the contact stated that after inspecting the vehicle she noticed that there was a piece of metal rubbing against the tire. the vehicle was taken to the dealer who diagnose that the rear wheel well needed to be replaced. the vehicle was repaired. the manufacturer was made aware of the failure who did not offer any assistance. the failure mileage was 84,000. pmb
09/01/201286000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while driving 55 mph smoke emitted into the vehicle. the contact was able to maneuver to the shoulder when she noticed that flames were coming from under the vehicle right before it was completely engulf in flames. the police and fire department were contacted. the dealer was contacted who stated that the failure might had been cause by the torque converter and offered no assistance. the manufacturer was made aware of the failure who filed a report and did not offer any further assistance. the failure and current mileage was 86,000. pmb
08/08/201284000
 Tl- the contact owns a 2004 ford freestar. the contact stated that when she pressed the brake pedal, it would feel hot. the contact stated that she pulled over and noticed that there was a piece of metal rubbing against the tire. the vehicle was taken to the dealer for inspection and they stated that the rear well needed to be replaced. the vehicle was repaired. the manufacturer was notified and they stated that there was that could be done. the failure mileage was 84,000. ap
09/01/201286000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while driving 55 mph smoke emitted into the vehicle. the contact was able to maneuver to the shoulder when she noticed that flames were coming from under the vehicle right before it was completely engulf in flames. the police and fire department were contacted. the dealer was contacted who stated that the failure might had been cause by the torque converter and offered no assistance. the manufacturer was made aware of the failure who filed a report and did not offer any further assistance. the failure and current mileage was 86,000. pmb
09/01/201286000
 Tl- the contact owns a 2004 ford freestar. the contact stated that while driving at 55 mph smoke emitted inside the vehicle. the contact managed to pull over to the shoulder when she got out of the vehicle to inspect what was wrong with it. the front underneath of the vehicle was on cough fire and caused the vehicle to cough on flames. the police was notified who provided the contact with a report. the fire department was notified of the fire. the dealer was notified of the failure who stated that the possible failure was caused by the torque convertible and offered no assistance. the manufacturer was notified and who provided the contact with a case number 1411732482 and offered no additional assistance. the failure and current mileage was 86,000. lg
08/03/201283000
 Tl-the contact owns a 2004 ford freestar. the contact stated that the rear quarter panel on the driver side had excessive rust build up and as a result, the panel rubs on the tire while driving. the contact decided to remove part of the quarter panel in order to stop the tire from rubbing. the vehicle was taken to an independent mechanic who stated that the quarter panel needed to be replaced with new metal. the manufacturer was made aware of the failure who did not offer any assistance. the failure mileage was 83,000. pmb
08/03/201283000
 Tl-the contact owns a 2004 ford freestar. the contact stated the rear quarter panel on the driver side had excessive rust build up cause the panel to rub on the tire while driving. the contact pulled off part of the quarter panel to stop the tire rubbing. the contact took the vehicle to a local mechanic for a diagnostic test. the mechanic stated the quarter panel needed to replaced with new metal. the contact called the manufacturer. the manufacturer stated there was nothing they could do. the failure mileage was 83,000. jo
08/26/20121165421
 Left rear seat anchor was loose, so we looked. a large hole had rusted out of the inner fender causing the anchor to completely detach from the body. we took it in to get checked out and they agreed it had completely rusted through and the right side is also rusting out, although not the point of completely rusting through, yet. we are just thankful this was noticed when we were parked and not driving 65 mph causing an accident. *tr
08/26/2012116542
 Left rear seat anchor was loose, so we looked. a large hole had rusted out of the inner fender causing the anchor to completely detach from the body. we took it in to get checked out and they agreed it had completely rusted through and the right side is also rusting out, although not the the point of completely rusting through, yet. we are just thankful this was noticed when we were parked and not driving 65 mph causing an accident.
07/25/2012740001
 The rear left metal u-shaped post that is used to secure the front of the rear bench seat and is attached through the body by a metal plate in the rear wheel well fell out of the vehicle as the vehicle was moving at a speed of 10 miles per hour. the rear seat was folded into the floor at the time of the incident. the post and the attached plate fell out into the wheel well and then fell to the roadway. upon inspection, the edge of the metal plate, and much of the surrounding wheel well had rusted away causing the incident. the incident resulted in a large hole in the wheel well that goes clear though to the interior of the van. we brought the van to a local ford dealer for repair. they acknowledged seeing this issue recently in the same make, model, and year of van. they said they were unable to make a repair. they suggested taking the issue to a body shop. two local body shops were unable to make the repair. as it stands, the rear bench seat is unusable as it can't be secured in the upright position, and there is a hole near the exhaust system that makes the van unsafe to drive. it is frustrating that the same issue has been seen by ford, yet no suitable repair or solution has been provided. *tr
07/25/201274000
 The rear left metal u-shaped post that is used to secure the front of the rear bench seat and is attached through the body by a metal plate in the rear wheel well fell out of the vehicle as the vehicle was moving at a speed of 10 miles per hour. the rear seat was folded into the floor at the time of the incident. the post and the attached plate fell out into the wheel well and then fell to the roadway. upon inspection, the edge of the metal plate, and much of the surrounding wheel well had rusted away causing the incident. the incident resulted in a large hole in the wheel well that goes clear though to the interior of the van. we brought the van to a local ford dealer for repair. they acknowledged seeing this issue recently in the same make, model, and year of van. they said they were unable to make a repair. they suggested taking the issue to a body shop. two local body shops were unable to make the repair. as it stands, the rear bench seat is unusable as it can't be secured in the upright position, and there is a hole near the exhaust system that makes the van unsafe to drive. it is frustrating that the same issue has been seen by ford, yet no suitable repair or solution has been provided.
08/13/2012976031
 On 08/13/2012 tried to engage the third row folding seat to the full upright position. the drivers side latch for the third row seat would not engage. after further inspection i found the seat anchor to be loose. after i looked at the outside of the wheel well the plate that the anchor mounts to was completely corroded all the way around and the plate and anchor is detached from the vehicle and falling into the wheel well. there is now a big hole from the outside of the wheel well directly into the interior of the rear of the vehicle. the interior of the vehicle becomes soaked when driven in the rain. safety issue as our kids ride in the third row seat and there is no way to latch the seat safely now. *tr
08/13/201297603
 On 08/13/2012 tried to engage the third row folding seat to the full upright position. the drivers side latch for the third row seat would not engage. after further inspection i found the seat anchor to be loose. after i looked at the outside of the wheel well the plate that the anchor mounts to was completely corroded all the way around and the plate and anchor is detached from the vehicle and falling into the wheel well. there is now a big hole from the outside of the wheel well directly into the interior of the rear of the vehicle. the interior of the vheicle becomes soaked when driven in the rain. safety issue as our kids ride in the third row seat and there is no way to latch the seat safely now.
07/27/20121478381
 We had the 3rd row seat folded down for cargo space. upon pulling the seat back up, the left side of the seat wouldn't latch and the seat moved when someone was sitting on it. when my husband tried to secure the latch by folding the seat back down and then back up again - the entire left side latch and plate it's attached to fell into the wheel well. he had to reach up over the left rear wheel to remove the part and saw that there is now a hole in the wheel well that goes right into the van - you can literally see in the van! the latch unit: the plate it's bolted to and the metal section of the wheel well that the plate is welded to were completely rusted out. we can no longer use the back seat due to safety reasons. we are having a hard time finding someone to repair it. one person said we'd have to replace the entire wheel well. we read on line that ford has responded that there are no replacement parts for this issue because it wasn't manufactured to be replaced. now we have a van we can't get fixed, we can't use the 3rd row seats (we haul the neighbor's 2 kids in addition to our 2 kids to and from school), and gets wet on the inside when it's raining because of the open hole in the wheel well. *tr
07/27/2012147838
 We had the 3rd row seat folded down for cargo space. upon pulling the seat back up, the left side of the seat wouldn't latch and the seat moved when someone was sitting on it. when my husband tried to secure the latch by folding the seat back down and then back up again - the entire left side latch and plate it's attached to fell into the wheel well. he had to reach up over the left rear wheel to remove the part and saw that there is now a hole in the wheel well that goes right into the van - you can literally see in the van! the latch unit: the plate it's bolted to and the metal section of the wheel well that the plate is welded to were completely rusted out. we can no longer use the back seat due to safety reasons. we are having a hard time finding someone to repair it. one person said we'd have to replace the entire wheel well. we read on line that ford has responded that there are no replacement parts for this issue because it wasn't manufactured to be replaced. now we have a van we can't get fixed, we can't use the 3rd row seats (we haul the neighbor's 2 kids in addition to our 2 kids to and from school), and gets wet on the inside when it's raining because of the open hole in the wheel well.
07/07/201278507
 Tl-the contact owns a 2004 ford freestar. the contact stated that the third row seating anchor failed due to corrosion penetrating the rear wheel well on the driver
07/07/201278507
 Tl-the contact owns a 2004 ford freestar. the contact stated that the vehicle third row seat anchor failed due to corrosion, the corrosion penetrated the left rear wheel well. the manufacturer was not made aware of the failure. the vehicle was not taken to the dealer. the vehicle was not repaired. the failure and the current mileage was 78,507. li
07/25/20121450001
 Third row seat no longer latches securely, caused by corrosion from left rear wheel well area ruining body latching holding seat in place. *tr
07/25/2012145000
 Third row seat no longer latches securely, caused by corrosion from left rear wheel well area ruining body latching holding seat in place.
06/28/2012120000
 Tl* the contact owns a 2004 ford freestar. the contact stated that the rear wheel wells were completely rusted. the vehicle was taken to the dealer to be repaired and the contact was informed that the dealer would not touch the vehicle to avoid the liability. the rust had damaged the lugs for the seat belt anchors. the vehicle had not been repaired. the failure and current mileages were 120,000.
06/28/2012120000
 Tl- the contact owns a 2004 ford freestar. the contact stated that the rear wheel wells were completely rusted. the vehicle was taken to the dealer to be repaired and the contact was informed that the dealer would not touch the vehicle to avoid the liability. the rust had damaged the lugs for the seat belt anchors. the vehicle had not been repaired. the failure and current mileages were 120,000. kmj
06/28/2012120000
 Tl- the contact owns a 2004 ford freestar. the contact stated that the vehicle rear wheel wells have completely rusted out. the vehicle was taken to the dealer to be repaired and was informed that the dealer would not touch the vehicle to avoid the liability. the rust has damaged the lugs for the seat belt anchors. the vehicle had not been repaired. the failure and current mileages were 120,000. dt
05/19/201271065
 While turning a corner we heard a loud noise coming from the left rear tire. after getting home we pulled the left rear tire off to inspect the brakes, which were fine. we did notice that the wheel well was rusting out around the third row seat latch. the latch was loose and upon further inspection did not lock the third row seat into place. when carrying passengers in the back seat the latch is pushed out far enough that it actually rubs on the rear tire, which could result in tire failure.
05/12/201291000
 3rd row bench seat, drivers side u type bolt bracket( the inside piece that the rear seat locks into)...competely rusted through and partialy fell onto the tire and brake assembly. the passengers side in also cracked and brittle. the van still runs fine but we cannot use the 3rd row seat. our childeren were sitting on it when it finally broke and fell on the wheel. it made a hell of a noise . we were able to get stopped without much of a problem.
05/19/201271065
 While turning a corner we heard a loud noise coming from the left rear tire. after getting home we pulled the left rear tire off to inspect the brakes, which were fine. we did notice that the wheel well was rusting out around the third row seat latch. the latch was loose and upon further inspection did not lock the third row seat into place. when carrying passengers in the back seat the latch is pushed out far enough that it actually rubs on the rear tire, which could result in tire failure.
05/12/201291000
 3rd row bench seat, drivers side u type bolt bracket( the inside piece that the rear seat locks into)...competely rusted through and partialy fell onto the tire and brake assembly. the passengers side in also cracked and brittle. the van still runs fine but we cannot use the 3rd row seat. our childeren were sitting on it when it finally broke and fell on the wheel. it made a hell of a noise . we were able to get stopped without much of a problem.
03/25/201275600
 Rear 3rd row seat latch is completely rusted through making the rear seat completely unsafe and unusable. could cause serious injuries in a accident if rust goes undetected, vehicle is kept in garages and well maintained.
04/01/2011115000
 Left rear seat no longer latches making it unsafe. the seat no longer latches because latch that was fastened to the left rear wheel well has rusted completely off the wheel well.
03/05/2012128641
 Noticed inside carpet was wet on the rear left side, removed the inside rear wheel panel and found the third row seat latch had completely rusted through to the outside of the car allowing water to enter the cab space and now the third row seat is unsafe due to the seat not being able to latch.
02/07/201297000
 Tl- the contact owns a 2004 ford freestar. while parked, the contact noticed that the third row rear seat would not latch in place. the contact inspected the vehicle and discovered that the seat anchor in the third row seat was corroded and bore a hole into the seat anchor. the vehicle was taken to the dealer for diagnostics where the technician advised that there was not a repair available for the failure. the vehicle was not repaired. the approximate failure mileage was 97,000. kmj
04/01/2011115000
 Left rear seat no longer latches making it unsafe. the seat no longer latches because latch that was fastened to the left rear wheel well has rusted completely off the wheel well.
03/05/2012128641
 Noticed inside carpet was wet on the rear left side, removed the inside rear wheel panel and found the third row seat latch had completely rusted through to the outside of the car allowing water to enter the cab space and now the third row seat is unsafe due to the seat not being able to latch.
02/07/201297000
 Tl- the contact owns a 2004 ford freestar. while parked the contact noticed the third row rear seat would not latch in place. the contact inspected the vehicle and noticed the seat anchor in the third row seat had corroded a hole into the seat anchor. the vehicle was taken to the dealer for diagnostic. the technician stated there was not repair for the failure. the vehicle was not repaired. the approximate failure mileage was 97,000. ds
04/01/2011115000
 Left rear seat no longer latches making it unsafe. the seat no longer latches because latch that was fastened to the left rear wheel well has rusted completely off the wheel well.
03/05/2012128641
 Noticed inside carpet was wet on the rear left side, removed the inside rear wheel panel and found the third row seat latch had completely rusted through to the outside of the car allowing water to enter the cab space and now the third row seat is unsafe due to the seat not being able to latch.
04/01/2011115000
 Left rear seat no longer latches making it unsafe. the seat no longer latches because latch that was fastened to the left rear wheel well has rusted completely off the wheel well.
03/05/2012128641
 Noticed inside carpet was wet on the rear left side, removed the inside rear wheel panel and found the third row seat latch had completely rusted through to the outside of the car allowing water to enter the cab space and now the third row seat is unsafe due to the seat not being able to latch.
12/29/2011100000
 Tl- the contact owns a 2004 ford freestar. the contact stated that the third row seat latch would not latch properly due to corrosion. the vehicle was inspected by an independent mechanic who advised the contact that the latch would have to be replaced. the manufacturer was contacted and they advised her that the part needed for the repair was not made for replacement. the failure mileage was approximately 100,000. kmj
12/29/2011100000
 Tl-the contact owns a 2004 ford freestar. the contact stated that the 3rd row seat latch would not latch properly due to corrosion and was unsafe for anyone to sit back there. the vehicle was inspected by an independent mechanic and they advised her that the latch would have to be replaced. the manufacturer was contacted and they advised her that the part needed was not made for replacement. the failure mileage was approximately 100,000. tb
12/26/2011137000
 Tl - the contact owns a 2004 ford freestar. the contact stated that the hook that held the rear driver side convertible bench seat in place was completely corroded. the contact mentioned that the damage was so severe that it rusted through the body of the vehicle. the vehicle was not taken to the dealer. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was no longer under warranty. the vehicle was not repaired. the failure and the current mileage was 137,000. kmj
12/29/2011100000
 Tl-the contact owns a 2004 ford freestar. the contact stated that the 3rd row seat latch would not latch properly due to corrosion and was unsafe for anyone to sit back there. the vehicle was inspected by an independent mechanic and they advised her that the latch would have to be replaced. the manufacturer was contacted and they advised her that the part needed was not made for replacement. the failure mileage was approximately 100,000. tb
12/26/2011137000
 Tl - the contact owns a 2004 ford freestar. the contact stated that the hook that holds the rear driver side convertible bench seat in place was completely corroded. the contact mentioned that the damage was so severe it rusted through the body of the vehicle. the vehicle was not taken to the dealer. the manufacturer was made aware of the failure who did not offer any assistance since the vehicle was no longer under warranty and referred him to nhtsa. the vehicle was not repaired. the failure and current mileage was 137,000. pm
12/14/2011
 Paint peeling off roof and hood ,looks like they used two different primers
12/04/201192300
 Upon opening the folding third row seat, the bottom latch failed to engage with the seat. further inspection showed that the entire latch panel had rusted away from the body of the car and was sitting in the wheel well. there is now a hole in the side of the van and the third row seat is unusable. at 7 years old, this level of rust is very premature.
10/22/2011105000
 Tl* the contact owns a 2004 ford freestar. the contact stated that water had entered and remained in the rear cargo area. the contact inspected the vehicle and found corrosion in the rear fender well and the third row seat latch. the rear panel was not installed correctly and caused water to penetrate the cargo area. the vehicle was not repaired. the failure and the current mileage was 105,000.
10/22/2011105000
 Tl-the contact owns a 2004 ford freestar. the contact stated that water had entered and remained in the rear cargo area. the contact inspected the vehicle and found corrosion in the rear fender well and the third row seat latch. the rear panel was not installed correctly and caused water to penetrate the cargo area. the vehicle was not repaired. the failure and the current mileage was 105,000. kmj
10/22/2011105000
 Tl-the contact owns a 2004 ford freestar. the contact stated the vehicle rear cargo area was holding water. the contact inspected the vehicle and found corrosion in the rear fender well, and the rear third row seat latch. the vehicle rear panel was not installed correctly and caused water the penetrate the cargo area. the vehicle was not repaired. the failure and the current mileage was 105,000. li
08/02/201146000
 Drivers side front door will not close. exercised all locks open and closed multiple times, but door will not latch closed. major safety issue.
06/16/2009685961
 The paint on my 2004 ford freestar van is bubbling and peeling off of the roof of the vehicle. *tr
03/28/20047502
 Plastic molding along the running boards broke off. as a result, the sliding door malfunctioned, locking occupants inside vehicle. *ak
STRUCTURE - BODY - DOOR
11/10/200790003
 In nov, 2007 my 7 year old granddaughter started to exit the back passenger van door. the door opened and she was about half way out the door when it started to close on her. my husband had already got out of the van and was able to stop the door from closing on her. it did not automatically stop and go back on contact. then in dec my sister-in-law was also starting to exit the van from the same door and the same thing happened to her. the door opened, hesitated and then started to close on her. on april 6, 2008 my 80+ mother opened the rear passenger van door and started to enter the van. the door started closing on her. her left foot was already in the van and the door closure caused her to fall backwards onto the pavement. her left foot was tangled under the passenger seat. her cousin was already seated on the other side and was able to get the door stopped before it hurt her leg any worse. she had landed on her lower back and was sore, stiff and unable to sit comfortably for about a week. i made an appt with the local ford dealer to see if they could find a problem. the first time i took it in, they could not duplicate the problem. i told them it was intermittent,most of the time it worked. when i picked the van up i had the service manager walk out with me, and i showed him how we opened the door from the outside and the door opened and immediately started to close. the service group was testing it by using the buttons on the remote. they tested the van again and found codes of b2589, b2592 and b2594 in the computer for the sliding doors. they then found the latch and sensor assembly were sticking and shorted out. they told us they found the codes in both doors, even though we hadn't had any problems with the sliding door on the drivers side. the only way to fix the problem was to replace both sides rear sliding door cables and latch assemblies. this is for a 2004 freestar van with only 10,072 miles! it cost us $736.41 to have this fixed. *tr
STRUCTURE - BODY - DOOR - HINGE AND ATTACHMENTS
06/15/20051540003/10/2005
 We just purchased a 2004 ford freestar. i am 67 and went to get out of the back door and the driver accidentally pushed the button to close the door.it crushed my leg, as there is no way to stop the door. there are no safety switches. everyone in the car tried to help and the door would not go back. this would have killed a child or my 89 year old mother. there needs to be a recall. my husband has size 14 shoes and when he tried to get out the same door, his knee almost hit the door closing button...and he was watching out for the problem.
06/20/20045004
 The power sliding door, upon opening the door, and depressing the electrical button to close the door it will not stop. it continues to close until you are caught in the door.*ak
STRUCTURE - FRAME AND MEMBERS
07/01/2011144000
 The part of the frame that holds my front passenger steering and wheel assembly in place has failed. my mechanic said it's the exact same problem that they recalled ford windstar vans for - but since my vehicle is a ford freestar van there's no recall? my van is now undrivable!
STRUCTURE - FRAME AND MEMBERS - UNDERBODY SHIELDS
02/09/20131200001
 The panel that the latch is bolted to was corroded and came of leaving no place for the latch on the drive's side to attach to. *tr
10/13/20121160001
 Noticed a panel loose in the rear driver's side wheel well while removing the wheel. the panel was completely rusted and separated from the wheel well, with only something attached to it on the interior keeping it from falling off. took it to a body shop, where it was determined that this panel is the rear seat anchor and the seat latch was the only thing keeping it from falling off. the estimate for repair is $906.99. the rear seat anchor was removed and the hole temporarily taped closed, and the rear seat is not safe and cannot be used. contacted the dealer to see if any recalls exist for this condition and was told there are none. currently trying to decide whether or not to repair the vehicle. the vehicle is well maintained and the condition of this panel/anchor is unusual when compared to the rest of the vehicle. *tr
10/04/20121256821
 Our two daughters where in the rear seat and complained of a bad smell as if something burning. at about that same time i noticed hearing a rubbing noise every time we turned left. when we got home shortly after i looked up under the inner fender of the rear left wheel and found a large steel plate loose and rubbing the tire. it was so rusty you could see the interior plastic panels and insulation. at that time i put away the rear seat and noticed the left side anchor was totally loose and when i asked the girls if they noticed that the seat moved they stated that they did notice it move but never said anything about it. there is now a hole in the car wheel well and we cannot use the back seat. we have a bungee cord latched to the two seat anchors holding them inward to keep the metal plate from rubbing the tire. the van is now limited to four passengers and i am concerned about carbon monoxide entering the car. *tr
08/31/20121649001
 I was rotating my tires and noticed that inside each rear wheel well there was a panel patched in from the factory that was rusting terribly, with the drivers side being much worse and almost completely falling off the body. with some further investigation i discovered that the panel actually holds the anchors for the rearmost folding seat. as i stated, the drivers side is almost rusted off the car and there is a giant hole that is letting water and snow inside the van and ruining the carpet and padding. i frequently carry multiple children,some in child safety seats, and could not imagine what would happen during a collision if the rear seat anchor were to separate from the van. i seriously hope that there is some kind of recall, as this vehicle is not yet 10 years old and the rest of the body is still in great shape. this is not just a surface rust issue, it is a safety hazard to anyone owning this type of van and the manufacturer should be held responsible for fixing it as i'm sure the repair is not easy or cheap. *tr