The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗2006 Ford Freestar engine problems
severe 14 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
14
Recalls
0
Avg fix
$3,100
1fire
What stands out
No new NHTSA engine complaint has been filed on this vehicle in over 13 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
CUSTOMER SATISFACTION PROGRAM 06B37. CRANK POSITION SENSOR CONNECTOR INSPECTION. THE CRANKSHAFT POSITION SENSOR HARNESS CONNECTOR MAY NOT HAVE BEEN FULLY SEATED IN THE CRANKSHAFT POSITION SENSOR. IF THE CRANKSHAFT POSITION SENSOR BECAME DISCONNECTED, THE ENGINE WOULD STOP.
full bulletin at NHTSA ↗ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report sudden loss of all engine power while driving at highway speeds, with stalling occurring without warning at speeds ranging from 45 to 110 mph. Several complaints describe the vehicle losing power in heavy traffic or on interstates, creating dangerous situations. Multiple owners tie these failures to wet weather; one owner documented that his vehicle only became undrivable when it rained, with the engine shuddering, shaking, and knocking. A Ford dealer identified a known manufacturing defect: incorrect sealer application to the PCM and poor positioning relative to windshield runoff allowed water intrusion, causing the control module to issue random commands.
Transmission-related failures appear at mileages from 105,000 km to 126,000 miles, with one owner facing a $2,975 replacement bill and another reporting $20,000+ in repair costs. Repair costs are consistently high, and one owner reported Ford Canada denied warranty coverage on a 2006 model outside the 2004–2005 recall scope.
Additional electrical gremlins plague these vehicles: stereo presets reset repeatedly despite two replacements, a turn signal burned out seven times, the AC blower squeals and required two replacements, and the starter engages intermittently. One owner expressed concern about fire hazard due to suspected wiring issues. A single complaint reported an engine compartment fire that burned the vehicle completely while on the interstate.
Same Ford Freestar engine reports on nearby years: 2005
Failure modes owners describe
Transmission failure and loss of power while driving
Complete transmission shutdown or torque converter failure, often resulting in sudden loss of engine power and inability to accelerate or restart the vehicle.
When: 105,000 km; 110,000 miles; 118,744 miles; 126,486 miles; variable mileage
Symptoms owners cite: sudden loss of all power while driving; vehicle stalls without warning; jerking and bucking followed by power loss; inability to accelerate after restart; transmission shifts randomly for no reason; intermittent power loss especially after rain
Codes mentioned: Check Engine Light illumination
Repairs/costs cited: $2,975 transmission replacement at AAMCO (owner #1); torque converter replacement suspected (owner #9); sensor replacement recommended by dealer (owner #8) but not performed; repair costs totaled approximately $20,000+ for one owner (owner #5)
Recalls/TSBs owners mention: Ford Canada denied warranty claim stating the vehicle was out of recall scope; dealer stated they were no longer fixing the issue (owner #6); Ford Service Bulletin identified water intrusion into PCM as root cause for some instances (owner #3)
Water intrusion into PCM causing electrical and drivability failures
Manufacturing defect where moisture enters the Powertrain Control Module due to incorrect sealer application and poor PCM positioning relative to windshield runoff, causing erratic engine behavior and loss of function.
When: Throughout ownership, particularly triggered by rain
Symptoms owners cite: engine shudders and shakes when it rains; engine knock during wet weather; transmission shifts for no reason during rain; stalling out in traffic when it rains; vehicle becomes non-drivable in rain only; vehicle smells like burning when it rains; shaking and burning smell that gets worse over time with rain exposure
Codes mentioned: Check Engine Light flashing, random PCM error codes
Repairs/costs cited: Ford Service Bulletin resolved the issue by resealing the PCM and blocking water flow to prevent moisture intrusion (owner #3)
Recalls/TSBs owners mention: Ford Service Bulletin TSB identified the defect: incorrect sealer application on PCM and poor positioning relative to windshield runoff; repair followed Ford bulletin with improved sealing
Engine misfire and hard starting
Engine misfires at startup and struggles to start, requiring multiple restart attempts before the engine catches.
When: 30,000 miles; variable throughout ownership
Symptoms owners cite: engine misfires at start-up; hesitation during startup; requires 1 to 2 retry attempts before engine starts
Recalls/TSBs owners mention: Vehicle still under powertrain warranty; dealer deferred diagnosis and repair
Intermittent electrical issues (stereo, lights, starter, AC blower)
Multiple electrical components fail intermittently or repeatedly, including stereo presets, turn signals, starter, and rear AC blower, suggesting wiring or grounding defects.
When: Throughout ownership
Symptoms owners cite: stereo presets reset intermittently; stereo clock resets to 12:00; stereo volume fluctuates on its own via rear controls; rear driver side turn signal burns out repeatedly (7 replacements); outside temperature probe reads incorrectly; starter has intermittent engagement problems; rear AC blower squeals intermittently (replaced twice, issue persists); muffled thump sound from air cleaner area
Repairs/costs cited: Stereo replaced twice (owner #2); turn signal replaced 7 times; AC blower replaced twice; multiple dealer visits yielded no resolution; PCM checked and not found wet or damaged
Recalls/TSBs owners mention: Multiple dealer visits without resolution; one dealer deemed the air cleaner thump sound normal
Engine fire under hood
Engine compartment fire while driving on interstate; fire could not be extinguished and resulted in total loss of vehicle.
When: While driving on interstate at unknown mileage
Symptoms owners cite: fire under hood; unable to open hood; total vehicle burnout
Repairs/costs cited: Vehicle totaled; no repair possible
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Air conditioner, right side passenger door window, moter mounts. *tr
Had engine trouble with your 2006 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 2006 Ford Freestar?
It's a meaningful issue. 14 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 13 complaints that reported odometer mileage, most engine failures cluster between 50,000 and 126,486 miles, with the median around 110,000. A quarter of owners report trouble before 50,000; a quarter make it past 126,486. 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/2006/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.