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2004 Ford Freestar CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Ford Freestar car and truck
repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Ford Freestar automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
General Service Domestic Vehicles -> 2003-04 -> Pressure Gauge Indication
Vehicle: 2004 Ford Freestar 3.9 V6 GAS
Due to the different types of models and systems, typical pressure gauge indications should be used as a guide only. Refer to the "Performance Tests" or "System Pressure Check" for the particular model being tested. When indi...
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BRAKE SERVICE PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Disc Brakes -> Inspection -> Brake Bleed -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2004 Ford Freestar 3.9 V6 GAS
Brake Linings
Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if required).
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if required, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Shutoff Switch Location -> Freestar & Monterey
Vehicle: 2004 Ford Freestar 4.2 V6 GAS
The inertia switch is locate...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
CV AXLE SHAFT, Replace -> Front
Vehicle: 2004 Ford Freestar 4.2 V6 GAS
Front
- With vehicle in NEUTRAL, position on a hoist.
- Remove front wheel and tire assembly.
- Remove bolts and position disc brake caliper aside.
- Remove front axle wheel hub retainer nut and washer.
- Remove lower control arm bal...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Diagnosis & Testing -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> Symptom Test
Vehicle: 2004 Ford Freestar 4.2 V6 GAS
Symptom Test
Refer to Fig. for Symptom Test Chart.
Intermittent & Poor Connections
Intermittents
Most intermittents are caused by faulty electrical connections or wiring. Inspect for the following:
- Wiring broken inside insulation.
- Poor connection between male and female terminal at connector.
- Poor terminal to wire connection. Some conditions which fall under this are:
- Poor crimps.
- Poor solder joints.
- Crimping over wire insulation rather than wire.
- Corrosion in wire to terminal contact.
- Wire insulation which is rubbed through. This causes an intermittent short as bare area touches other...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Starter, Replace
Vehicle: 2004 Ford Freestar SE 3.9 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove starter terminal cover, then solenoid S terminal retaining nut and electrical connector.
- Remove battery ground cable retaining from starter mounting stud, then cable.
- Remo...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1999-2003 Windstar & 2004-07 Freestar & Monterey
Vehicle: 2004 Ford Freestar SE 3.9 V6 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Open the hood.
- Release the cabin air filter cover retaining snaps, then remove the cover. The cabin air filter cover is located on the ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Ford Motor Co. Trucks -> Low Fuel Level Warning Lamp ->
Vehicle: 2004 Ford Freestar 4.2 V6 GAS
When fuel level drops below a predetermined level, the CHECK GAUGE indicator should light. The CHECK GAUGE indicator shoul...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Ford Freestar 4.2 V6 GAS
- Drain coolant into a suitable container.
- Disconnect MAF sensor, then remove air filter outlet tube.
- Remove air cleaner housing assembly, then air filter housing bracket.
- Diconnect harness retainers from fan shroud.
- Disconnect upper radiator hose.
- Remove radiator alignment pins as follows:
- Tie radiator and condenser to upper radiator support separately, using mechanic wire.
- Allow 2 inches of slack in condenser wire to allow for movement.
- Remove radiator alignment pins.
- Disconnect radiator vent hose from radiator.
- Disconnect degas bottle return hose.
- Disconnect lower radiator hose.
- Detach t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Ford Freestar AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Ford Freestar SE 3.9 V6 GAS
- Use drive belt tensioner pulley bolt to rotate drive belt tensioner counterclockwise and remove drive...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Ford Freestar AUTOMOBILES
Component location diagrams for most 2004 Ford Freestar cars and light trucks sold in the U.S. from 1990+.
 Body Components Diagram for 2004 Ford Freestar 4.2 V6 GASComponents on diagram: |
 Engine Compartment Components Diagram for 2004 Ford Freestar 3.9 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Ford Freestar AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Ford Freestar cars and light trucks sold in the U.S.
 2004 Ford Freestar 4.2 V6 GAS Wiring DiagramComponents on diagram: |
 2004 Ford Freestar 3.9 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Ford Freestar AUTOMOBILES
OEM TSB listings for most 2004 Ford Freestar cars and light trucks sold in the U.S. from 1985+.
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Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 2004 Ford Freestar 4.2 V6 GAS |
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Document: SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION - SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC) Vehicle: 2004 Ford Freestar 4.2 V6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Ford Freestar AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Ford Freestar cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Ford Freestar cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Ford Freestar cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Ford Freestar cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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