Drove through a puddle and the engine quit. Apparently, the water splashed the on board computer (PCM). I towed vehicle to the dealer and they implemented the Ford technical service bulletin (tsb) reference number(s): 06-14-10, vehicle worked fine until the fall of 2014. Now the vehicle won't start at all if it sits out in the rain. If it does the water gets into the PCM and prevents it from…
2005 Ford Freestar engine problems
severe 50 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
50
Recalls
0
Avg fix
$3,100
2crashes
1fire
When does it fail?
Of the 50 engine complaints filed for the 2005 Ford Freestar, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 50 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA engine complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
The failure pattern owners describe
Buyer takeaway: The 2005 Freestar has well-documented transmission and engine stalling issues, with water intrusion into the engine computer being a recurring problem in wet climates. Expect potential $2,000+ transmission and engine repairs even after recall work; verify recall completion and be cautious in areas with moisture exposure.
The 2005 Freestar exhibits a constellation of engine and transmission faults that owners describe as safety hazards. The most frequent complaint is sudden, unwarned engine stalling while driving—often at highway speeds—accompanied by loss of power steering and braking. Owners report stalling 4–8 times over months, with no check-engine codes set and dealer technicians unable to reproduce or diagnose the problem.
Water intrusion into the powertrain control module (PCM) emerges as a chronic root cause, particularly in wet climates. Owners mention that heavy rain, puddles, or snow trigger stalling, jerking, and sputtering. Ford's TSB 06-14-10 addresses PCM water sealing, but many owners report the fix fails again within months or years—a permanent design flaw rather than a true repair.
Transmission problems run parallel: torque converter failures cause sudden loss of forward and reverse power; some occur shortly after the official recall replacement (NHTSA 12V-006), and owners report Ford's warranty denial when mileage exceeds 12,000 miles from recall service, even within 12 months. Shifting faults, violent jerking during gear changes, and inability to move appear across mileages. Multiple owners spent $800–$2,700 on transmission work only to face recurrence.
Alternator failures and unexplained stalling (no code set) compound the reliability picture. One owner's van required alternator replacement twice in eight weeks. Repair shops struggle to isolate root causes; some owners endured three or more shop visits with different diagnoses each time.
The pattern is consistent: owners feel unsafe driving these vans on highways and in wet weather, and repeat repairs fail to restore confidence.
Same Ford Freestar engine reports on nearby years: 2006
Failure modes owners describe
Torque Converter Failure
Transmission loses forward and/or reverse power without warning, sometimes after recall replacement. Owners report sudden loss of motive force, inability to shift or move, and complete power loss mid-drive.
When: Varies; one owner at 87,670 miles (within 12 months of recall but 200 miles past 12,000-mile recall warranty limit); another after recall replacement at lower mileage; some report failure years after purchase
Symptoms owners cite: Sudden loss of forward/reverse power while driving; Unable to shift into gear or move vehicle; Engine continues running but transmission unresponsive; Complete power loss requiring tow
Codes mentioned: Transmission failure codes (specific codes not stated in narratives)
Repairs/costs cited: Transmission/torque converter replacement $2,259.84–$2,700; some covered under recall (NHTSA 12V-006, Safety Recall 11S25); warranty limited to 12 months or 12,000 miles from recall date per Ford
Recalls/TSBs owners mention: Ford issued recall 12V-006 (11S25) for torque converter; however, warranty coverage denied when mileage exceeded 12,000 miles from recall repair date, even if within 12-month period. One owner pursued repair outside Ford after denial.
Engine Stalling—Water-Damaged PCM
Engine stalls suddenly while driving, particularly in wet conditions (rain, snow, puddles), due to water intrusion into the powertrain control module (PCM). Owners report multiple stalls and difficulty restarting; problem recurs even after repair attempts.
When: Varies by owner; one after driving through puddle; others after heavy rain or wet snow; problem recurring months or years after initial repair
Symptoms owners cite: Engine cuts off without warning while driving at 25–70 mph; Loss of power steering and brake assist when stalling; Difficulty restarting; intermittent starting in wet weather; Symptoms worsen in rain, wet snow, high humidity; RPM drop as if fuel-starved but no hesitation; No warning lights or inconsistent check-engine codes; Jerking/sputtering before stall
Codes mentioned: No codes or intermittent codes, Check-engine light absent or blinking without stored codes
Repairs/costs cited: Mechanics implemented TSB 06-14-10 (engine/transmission driveability); water drying, PCM sealing, or PCM replacement ($1,500–$2,500 quoted); one owner dried PCM and sealed it three times with repeated failure
Recalls/TSBs owners mention: Ford issued TSB 06-14-10 addressing PCM water intrusion; no recall issued despite numerous online complaints. Dealers cite poor hood/cowl drainage design; one owner saw dealers recommend cowl sealing and TSB repair; problem described as chronic (recurs within 1–2 years by some accounts)
Transmission Shifting/Drive Loss Issues
Vehicle fails to engage or maintain drive/reverse gears, jerks violently during shifting, or loses power during gear transitions. Some owners report stuck in first or second gear only, loss of RPM control, or inability to move after stalling.
When: Various mileages: 20,000–180,000 miles; some within weeks of purchase or shortly after engine work
Symptoms owners cite: Will not accelerate forward or in reverse; Stuck in low gear (first or second only); Violent jerking during shifts or at stop lights; Engine RPMs race then slam into gear; Engine cuts out during shift from first to second gear; Interior lights flicker; vehicle stalls at speeds above 15–20 mph; Transmission shifts erratically or not at all
Codes mentioned: Transmission light illumination, 2nd gear fault (one specialist diagnosis)
Repairs/costs cited: Transmission replacement $1,732–$2,700; some repairs included overdrive shaft sensor, spark plugs/wires ($800+), crankshaft/speed sensor replacement, transmission seal replacement, wiring harness diagnosis
Recalls/TSBs owners mention: Dealers unable to diagnose many cases; multiple visits and parts replacements did not resolve issues for some owners; one owner needed transmission specialist to diagnose 2nd-gear failure after dealer could not
Engine Stalling—Undetermined Cause (No Diagnostic Code)
Engine shuts off suddenly and without reproducible codes, sometimes after dealer attempts multiple repairs. Loss of power steering and brakes when stalling occurs; vehicle becomes unsafe to drive.
When: Various mileages; some owners report 5–8 occurrences within 12 months; one owner reported onset after engine replacement and subsequent transmission jerking
Symptoms owners cite: Engine shuts off without warning while driving; Loss of power steering and brake control; No check-engine light or code set; Stalls at stop sign or idle; Can restart but stalls again shortly after; Occurs multiple times in short driving periods
Codes mentioned: No codes or 'No codes' per dealer
Repairs/costs cited: One owner: alternator replacement $442–$297.68 twice; motherboard (engine control module) replaced; transmission replacement $1,732. Repairs did not resolve stalling.
Recalls/TSBs owners mention: Dealers unable to reproduce or diagnose; one owner left vehicle at dealer for extended periods (9/10/09–11/12/09, 11/15/09–2/5/2010); no lasting repairs provided. Owner reported 8 stalls in 12 months despite multiple service visits.
Sudden Power Loss/Hesitation—Acceleration Issue
Van loses acceleration power, hesitates to go forward, or will not accelerate beyond 40 mph. Often accompanied by pinging/knocking noise and loss of speed on highway merges.
When: Varies; one owner at time of purchase for used vehicle; another after EGR, plug, wire, fuel filter replacements
Symptoms owners cite: Will not accelerate or maintain speed above 40 mph; Pinging/knocking sound when pressing accelerator; Loss of pulling power/sudden deceleration from 45 mph to 20 mph; Cannot merge safely on highway; Hesitation when pressing gas pedal
Codes mentioned: Check-engine light (one owner)
Repairs/costs cited: One owner: EGR valve replacement, spark plugs/wires, fuel filter replacement—none resolved issue; out-of-pocket costs accumulating with no fix
Recalls/TSBs owners mention: No manufacturer assistance mentioned; dealer unable to resolve after multiple component replacements
Alternator Failure
Alternator fails, causing battery drain, power surges, and loss of electrical power while driving. One owner reported failure twice within two months.
When: One owner reported 8/9/10 and 10/9/10 within ~2 months; another 11/1/10
Symptoms owners cite: Power surge then power loss; Battery failure; Loss of electrical power while driving on highway; Vehicle stranded, required tow
Codes mentioned: Battery/charging system fault (implied by symptoms)
Repairs/costs cited: Alternator replacement $442, $297.68; new battery also required in at least one case; vehicle stranded on roadway, owner stuck overnight in unsafe location
Recalls/TSBs owners mention: None mentioned
Engine Failure/Seizure
Complete engine failure requiring replacement. One owner cited defective intake manifold gasket allowing antifreeze to contaminate oil and seize engine.
When: One owner at 47,000 miles
Symptoms owners cite: Engine failure requiring full replacement; Engine seized (bearings destroyed)
Codes mentioned: Engine seizure (mechanical failure, not code-based)
Repairs/costs cited: Engine replacement $5,100; one owner reported intake manifold gasket defect causing coolant leak into oil pan
Recalls/TSBs owners mention: None mentioned; one owner reported Ford refusing replacement when vehicle was 121 miles out of warranty
Charcoal Canister Cracking
Charcoal canister cracks despite no visible external damage, requiring repeated replacement. Owner questions poor placement of component.
When: One owner: three weeks after purchase of used vehicle; cracked again within weeks
Symptoms owners cite: Gas cap warning light illuminates; Check-engine light illuminates; Charcoal canister cracked with no visible external damage
Codes mentioned: Gas cap/emissions warning code
Repairs/costs cited: Canister replacement ~$500 per owner estimate; no warranty coverage
Recalls/TSBs owners mention: Ford refused to cover or investigate; owner questioned poor design placement of component
Engine Fire
Engine caught fire without warning while vehicle was stationary.
When: One owner at 122,000 miles
Symptoms owners cite: Fire ignition without warning
Repairs/costs cited: Vehicle involved in fire; fire department response required
Recalls/TSBs owners mention: Manufacturer not notified per report
Synthesized from 50 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Had engine trouble with your 2005 Ford Freestar?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2005 Ford Freestar?
It's a meaningful issue. 50 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 44 complaints that reported odometer mileage, most engine failures cluster between 66,495 and 120,000 miles, with the median around 95,000. A quarter of owners report trouble before 66,495; a quarter make it past 120,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Ford/Freestar.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.