FordFreestar2004Overview/ford/freestar/2004/base/

2004 Ford Freestar

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Freestar.

Body VANTransmission Automatic 4-spd

The 2004 Ford Freestar is a van utilizing a 4-speed automatic transmission, delivering EPA fuel economy of 15/21/18 mpg while requiring 5.0 quarts of 5W-20 API oil. This model year anchors the high end of the 2004-2007 complaint history with 1,227 total owner complaints, vastly exceeding the 64 complaints recorded for the 2007 model. Given that the Power Train emerges as the top complaint area among these issues and the vehicle carries 6 recalls, the 2004 Freestar occupies the least reliable position within this specific dataset.

Model year2007200620052004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy15/21/18 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 59 · 540 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 59 · 540 CCAOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length201.6 in
Overall width76.8 in
Overall height68.9 in
Wheelbase121.3 in
Curb weight4275 lb
Track (front / rear)63.8 / 62.6 in

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 21 / 18 mpg
DrivetrainFront-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-20 API engine oil, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 19.0-29.0 ft-lbs. The firing order is 1-4-2-5-3-6. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity13.5
Brake FluidDOT 3
Engine Oil5W-20 · API
Engine Oil Capacity5.0 qt
Engine Oil5W-20 · API
Engine Oil Capacity5.0 qt
Power Steering FluidATF

Engine torques

Crankshaft Pulley and/or Damper Bolts118 ft-lbs
Engine Flywheel Bolts59 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Engine Oil Pan Drain Plug19.0 ft-lbs
Engine Oil Pan Drain Plug19.0-29.0 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Front Wheel Hub184 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Curb Idle Speed (No Load)MT: 740, AT: 715 rpm
Curb Idle Speed Variance (No Load)MT: 40, AT: 15 rpm
Curb Idle Speed (No Load)800 rpm
Curb Idle Speed Variance (No Load)50 rpm
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.039-0.0.043 in
Spark Plug Torque20.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 2.25. With auxiliary A/C, 3.31. lbs
Oil GroupPAG
Oil Type46
Oil CapacityLess auxiliary A/C, 10.00. With auxiliary A/C, 12.00. oz
Standard BCI Group Number59
Standard BCI Cranking Performance540 cca
Optional BCI Group Number65

Service checks

Pressure Test20 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature188-195 °F
Pressure Test20 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature188-195 °F
Key ON Engine OFF (KOEO)67.0
Key ON Engine OFF (KOEO)30-45

Brakes

Torque Caliper to Bracket26 ft-lbs / 24 ft-lbs
Torque to Knuckle136 ft-lbs / 75 ft-lbs
Minimum Pad ThicknessFront: 0.118; Rear: 0.118 in
Rotor Minimum Machining1.14 in / 0.74 in
Rotor Discard at or Under1.11 in / 0.72 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
118 ft. lbs., Step 2: 33 degrees, Step 3: 10518 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
159 ft. lbs., step 2: 720 degrees, step 3: 37 ft. lbs., step 4: 9059 ft. lbs
Cylinder Head — tightening sequence 3 stages
114 ft. lbs.14 ft. lbs
229 ft. lbs.29 ft. lbs
336 ft. lbs.; Perform following 3 steps on each bolt; before moving to next bolt in sequence36 ft. lbs
1loosen 2-3 turns
2if long bolt30–37 ft. lbs
3turn 175-185 degrees; Proceed to next bolt in sequence175–185 degrees
Cylinder Head — tightening sequence 3 stages
1all bolts15 ft. lbs
2all bolts30 ft. lbs
3all bolts37 ft. lbs
1loosen 2-3 turn
2if long bolt33 ft. lbs
3180 degrees; Proceed to next bolt in sequence180 degrees
Main Bearings — tightening sequence 1 stages
137 ft. lbs., Step 2: 12037 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miBrake System (inspect) · Cabin Air Filter (replace) · Engine Coolant System Hoses (inspect) · Steering System (inspect) · Suspension System (inspect) · Transmission Assembly (inspect fluid level)
Every 30,000 miEngine Air Filter Element (replace) · Exhaust System (Complete) (inspect) · Fuel Filter (replace) · Temperature Controlled Seat Air Filter (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill)
At 100,000 miEngine Coolant System (drain, flush & refill)
Every 100,000 miAccessory Drive Belt (inspect) · PCV Valve (replace) · Spark Plugs (replace)
At 150,000 miDrive Belt (replace) · Transmission Fluid & Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Ford Freestar marks the debut of this generation, and the federal data reveals a clear peak in complaints (1,227) and recalls (6) compared to subsequent years, signaling typical first-year production challenges. Complaints drop sharply in 2005 (886) and continue declining through 2007, while recalls and investigations follow a similar downward trend, suggesting Ford addressed many early issues in later model years. The 2004 model’s complaints are overwhelmingly concentrated in the power train (727), a pattern not as pronounced in later years, alongside isolated concerns in braking and structural integrity. With 16 crash-related and 14 fire-related complaints, the 2004 Freestar’s safety record is notably more active than its successors. This year falls at the high-risk end of the generation’s quality arc, implying higher potential for unresolved or recurring issues. **Takeaway: The 2004 Freestar is the riskiest year to buy in this generation; opt for a 2006 or 2007 model if reliability is a priority.**

6
Open recalls
NHTSA campaigns
64
Service bulletins
Manufacturer communications
8
ODI investigations
Office of Defects Investigation
1,227
Owner complaints
16 involved a crash · 14 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 1,227 complaints on record, top 8 components.

Power Train727
Structure,Seats41
Seats31
Service Brakes, Hydraulic31
Structure29
Electrical System28
Engine19
Power Train,Electrical System19

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 5 campaigns on record for this vehicle.

13V081000SeatsReported 07/03/2013

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently… Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford…

12V006000Power Train:Automatic TransmissionReported 09/01/2012

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL. Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY…

Technical service bulletins NHTSA · verified

Showing 5 of 64 bulletins on record with NHTSA.

BulletinDateComponentSummary
SSM 460852016-09-21Engine And Engine CoolingThe Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing…
TSB1600692016-04-21SeatsSafety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers…
16-00692016-04-21SeatsFor 2004-2007 Freestar or Monterey vehicles Safety Recall 13S01 has been issued for…
TSB-14-01662014-09-09SeatsFORD/MERCURY: SAFETY RECALL REGARDING SHEET METAL SUPPORT FOR FOLDING 3RD ROW SEAT LATCH…
TSB-14-01442014-08-11Equipment Adaptive/MobilityFORD/MERCURY: SHEET METAL SUPPORTING FOLDING 3RD ROW SEAT LATCH STRIKERS WILL EXPERIENCE…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Freestar. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Freestar take?

5.0 qt of 5W-20 API MEETING FORD SPECIFICATION WSS-M2C945-A, per the factory manual.

Does the 2004 Freestar have open recalls?

NHTSA lists 6 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Freestar get?

EPA figures are 15 city / 21 highway / 18 combined mpg.