Ford Freestar 2004 to 2007 Factory Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Ford Model: Freestar Generation: First Generation Codes Platform Code: [,-] ๐ Introduction Market Position Target User: DIY enthusiasts and professional technicians seeking detailed repair and maintenance information. Competitive Analysis Advantage: Provides dealership-level diagnostic and repair procedures, offering a significant advantage over generic repair guides. Key Features Dealer Level Info: This manual is the exact same resource used by authorized Ford dealership technicians, ensuring accuracy and completeness. Comprehensiveness: Covers all service and repair aspects, from routine maintenance to complex overhauls, offering a complete solution for vehicle care. Accessibility: Available as a free download with no shipping costs, making it an extremely cost-effective resource. ๐ Manual Details Coverage Areas Applicability: Ford Freestar 2004, 2005, 2006, 2007 model years Page Count Estimated Pages: Extensive (typical factory workshop manuals for this era exceed 2000 pages) Manual Type Type: Factory Service Workshop Repair Manual Language Language: English Format File Format: PDF ๐ Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Electrical, Fuel System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle Chassis: Suspension System, Steering System, Restraint System, Brake System Body: Body (Interior and Exterior), Body Electrical System Comfort: Heating, Ventilation, Air Conditioning (HVAC) Emissions: Emission Control System Procedures Included General Maintenance: Oil changes, fluid checks and replacements, filter changes, tire rotation Engine Repair: Engine mechanical repairs, cylinder head service, piston and connecting rod service, crankshaft service, timing system repair, engine rebuilding Transmission Repair: Manual transaxle overhaul, automatic transaxle overhaul and repair Brake System Repair: Brake pad replacement, rotor service, caliper overhaul, brake line repair, ABS system diagnostics and repair Suspension Steering Repair: Shock absorber and strut replacement, ball joint service, tie rod end replacement, power steering system repair Electrical Diagnostics: Wiring diagrams, component testing, diagnostic trouble code (DTC) interpretation, module programming Body Work: Interior and exterior trim removal/installation, panel repair, door and window mechanisms HVAC Repair: Component replacement (compressor, condenser, evaporator), refrigerant system service, diagnostic procedures Technical Depth Depth: Comprehensive, covering from basic maintenance to complete system overhauls and advanced diagnostics ๐ Manual Specifications File Format Quality: PDF format ensures high quality, searchable text, and ease of navigation. Likely includes printable pages. Print Quality Digital Quality: High resolution, clear diagrams, and easily readable text, mirroring factory specifications. Binding Type Digital Binding: N/A (Digital PDF format) Paper Type Digital Paper: N/A (Digital PDF format) Compatibility Operating Systems: Windows (95/98/ME/XP/Vista/7), Linux, MAC โ๏ธ Engine Specifications Primary Engine Engine Options: The Ford Freestar was typically offered with V6 engines. Common options included: 3.9L V6 (3904Cc): Displacement: 3.9 Liters (approx. 238 cubic inches). Often referred to as the '3.9L Vulcan' or 'SOHC V6'. Power output typically around 193-201 horsepower and 220-240 lb-ft of torque. 4.2L V6 (4163Cc): Displacement: 4.2 Liters (approx. 254 cubic inches). This was a common engine for larger Ford vehicles. Power output typically around 201-205 horsepower and 260-270 lb-ft of torque. 4.0L V6 (3986Cc): Displacement: 4.0 Liters (approx. 243 cubic inches). Ford's 'Cologne' V6, used in some earlier models. Power output around 195-200 horsepower and 230-240 lb-ft of torque. Performance Horsepower Range: Approximately 193-205 hp, depending on the specific V6 engine option. Torque Range: Approximately 220-270 lb-ft, depending on the specific V6 engine option. Fuel System Injection Type: Electronic Fuel Injection (EFI), likely Sequential Multi-Port Fuel Injection (MPI). Fuel Type: Unleaded gasoline. Engine Mechanical Valvetrain: Overhead Valve (OHV) for the 4.2L and older 3.9L, and Single Overhead Cam (SOHC) for the later 3.9L V6. ๐ง Transmission Standard Transmission Type: Automatic Transaxle only. The Freestar was exclusively offered with an automatic transmission. Optional Manual Option: None. No manual transmission was available for the Ford Freestar. Features Automatic Transmission Model: Likely the Ford 4F50N or a similar 4-speed automatic transaxle, common in Ford/Mercury vehicles of this era. Transmission Fluid: Mercon V is the specified automatic transmission fluid for the 4F50N and similar transmissions. Refer to the manual for exact capacities and change intervals. ๐ Dimensions Exterior Body Style: Minivan Length: Approximately 200.5 inches Width: Approximately 79.3 inches Height: Approximately 68.6 inches Interior Seating Capacity: Available in 6, 7, or 8-passenger configurations. Cargo Cargo Volume Behind 3Rd Row: Approximately 20.2 cubic feet Cargo Volume Behind 2Nd Row: Approximately 65.5 cubic feet Cargo Volume Behind 1St Row: Approximately 133.4 cubic feet Weights Curb Weight: Typically ranges from 4,400 to 4,800 lbs, depending on configuration and engine. Gross Vehicle Weight Rating (Gvwr): Typically around 5,900 - 6,000 lbs. ๐ก๏ธ Safety Features Ratings NHTSA Frontal Crash Test Rating: 4-star rating for driver and front passenger (2004 model year). IIHS Side Impact Crash Test Rating: Good rating (2004 model year). Active Features ABS: Standard Anti-lock Braking System (ABS) on all four wheels. Traction Control: Optional Traction Control System (TCS). Electronic Stability Control: Optional Electronic Stability Control (ESP), often bundled with other advanced features. Passive Features Airbags: Standard front airbags for driver and front passenger....
Interior and exterior trim removal/installation, panel repair, door and window mechanisms
HVAC Repair:
Component replacement (compressor, condenser, evaporator), refrigerant system service, diagnostic procedures
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete system overhauls and advanced diagnostics
๐ Manual Specifications
File Format
Quality:
PDF format ensures high quality, searchable text, and ease of navigation. Likely includes printable pages.
Print Quality
Digital Quality:
High resolution, clear diagrams, and easily readable text, mirroring factory specifications.
Binding Type
Digital Binding:
N/A (Digital PDF format)
Paper Type
Digital Paper:
N/A (Digital PDF format)
Compatibility
Operating Systems:
Windows (95/98/ME/XP/Vista/7), Linux, MAC
โ๏ธ Engine Specifications
Primary Engine
Engine Options:
The Ford Freestar was typically offered with V6 engines. Common options included:
3.9L V6 (3904Cc):
Displacement: 3.9 Liters (approx. 238 cubic inches). Often referred to as the '3.9L Vulcan' or 'SOHC V6'. Power output typically around 193-201 horsepower and 220-240 lb-ft of torque.
4.2L V6 (4163Cc):
Displacement: 4.2 Liters (approx. 254 cubic inches). This was a common engine for larger Ford vehicles. Power output typically around 201-205 horsepower and 260-270 lb-ft of torque.
4.0L V6 (3986Cc):
Displacement: 4.0 Liters (approx. 243 cubic inches). Ford's 'Cologne' V6, used in some earlier models. Power output around 195-200 horsepower and 230-240 lb-ft of torque.
Performance
Horsepower Range:
Approximately 193-205 hp, depending on the specific V6 engine option.
Torque Range:
Approximately 220-270 lb-ft, depending on the specific V6 engine option.
Overhead Valve (OHV) for the 4.2L and older 3.9L, and Single Overhead Cam (SOHC) for the later 3.9L V6.
๐ง Transmission
Standard
Transmission Type:
Automatic Transaxle only. The Freestar was exclusively offered with an automatic transmission.
Optional
Manual Option:
None. No manual transmission was available for the Ford Freestar.
Features
Automatic Transmission Model:
Likely the Ford 4F50N or a similar 4-speed automatic transaxle, common in Ford/Mercury vehicles of this era.
Transmission Fluid:
Mercon V is the specified automatic transmission fluid for the 4F50N and similar transmissions. Refer to the manual for exact capacities and change intervals.
๐ Dimensions
Exterior
Body Style:
Minivan
Length:
Approximately 200.5 inches
Width:
Approximately 79.3 inches
Height:
Approximately 68.6 inches
Interior
Seating Capacity:
Available in 6, 7, or 8-passenger configurations.
Cargo
Cargo Volume Behind 3Rd Row:
Approximately 20.2 cubic feet
Cargo Volume Behind 2Nd Row:
Approximately 65.5 cubic feet
Cargo Volume Behind 1St Row:
Approximately 133.4 cubic feet
Weights
Curb Weight:
Typically ranges from 4,400 to 4,800 lbs, depending on configuration and engine.
Gross Vehicle Weight Rating (Gvwr):
Typically around 5,900 - 6,000 lbs.
๐ก๏ธ Safety Features
Ratings
NHTSA Frontal Crash Test Rating:
4-star rating for driver and front passenger (2004 model year).
IIHS Side Impact Crash Test Rating:
Good rating (2004 model year).
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all four wheels.
Traction Control:
Optional Traction Control System (TCS).
Electronic Stability Control:
Optional Electronic Stability Control (ESP), often bundled with other advanced features.
Passive Features
Airbags:
Standard front airbags for driver and front passenger. Optional side-impact airbags, and available overhead curtain airbags for all three rows.
Seat Belts:
Three-point seat belts with pretensioners for all seating positions. LATCH (Lower Anchors and Tethers for Children) system.
Child Safety Locks:
Standard rear door child safety locks.
๐ก Technology Features
Infotainment
Audio System:
Available with AM/FM stereo, CD player, and optional premium sound systems. Some models may have had satellite radio capability.
Rear Seat Entertainment:
Optional rear-seat entertainment system, typically including a DVD player and video screens.
Driver Assistance
Parking Sensors:
Optional rear parking assist sensors.
Backup Camera:
Less common in this era, but some later models or aftermarket installations may have featured a backup camera.
Connectivity
Auxiliary Input:
May have an auxiliary audio input jack for connecting portable media devices.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 to 7,500 miles or 6 months, whichever comes first, using synthetic blend or full synthetic oil. Consult the manual for precise recommendations based on driving conditions.
Tire Rotation:
Recommended every 5,000 to 7,500 miles.
Transmission Fluid Change:
Recommended around every 30,000 to 60,000 miles for automatic transmissions, depending on driving conditions. Crucial for longevity. The manual will specify exact intervals and procedures.
Coolant Flush:
Typically every 30,000 to 50,000 miles or 2 to 5 years. Refer to the manual for specific coolant type and interval.
Fluid Specifications
Engine Oil:
SAE 5W-20 is the most common viscosity for Ford V6 engines of this era. Check the oil fill cap or manual for confirmation. Capacity typically around 5-6 quarts.
Coolant:
Ford Premium Gold Coolant (or equivalent) is typically specified. A 50/50 mix of coolant and distilled water is standard.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Mercon ATF or a specific Ford power steering fluid, depending on the system. Consult the manual.
Known Issues
Transmission Problems:
Some owners have reported issues with the automatic transmission, including rough shifting or premature wear. Regular fluid changes are critical.
Suspension Wear:
Components like ball joints, tie rod ends, and struts can experience wear over time, leading to steering or ride quality issues.
Power Steering Leaks:
Potential for leaks in the power steering system, particularly at hoses or the pump.
Rear Air Suspension Issues:
Models equipped with rear air suspension may experience leaks or compressor failures.
๐ Vehicle History
Brand Heritage
Manufacturer:
Ford Motor Company, a long-standing American automotive manufacturer with a history dating back to 1903.
Model Evolution
Predecessor:
The Ford Freestar replaced the Ford Windstar minivan in Ford's lineup.
Generation Designation:
This represents the first and only generation of the Ford Freestar, produced from 2004 to 2007.