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Ford Freestar Transmission Problems

946 messages,  Last post on Dec 01, 2009 at 5:44 PM

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What is this discussion about? Ford Freestar, Mercury Monterey, Transmission, Van

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#937 of 946 Re: Where can you lodge a complaint? [henneberry] by jgenovese Nov 28, 2009 (1:08 pm)
Replying to: henneberry (Nov 27, 2009 10:52 am) henneberry,   File your complaint with NHTSA, via their website, the Center for Auto Safety, via their website, and of course, write to Ford. Don't stop there however; contact ALL of your elected representatives, both locally and nationally, and also your local media outlet.   Jim Genovese Annapolis, MD
#938 of 946 Re: resealling pcm 2004 monterey [chilll02] by nadineb Nov 29, 2009 (10:31 am)
Replying to: chilll02 (Nov 28, 2009 5:50 am) John,   In post 888, I linked the web site for diesel-dave.com, but not surprised to see the site has been taken down. You can find the entire TSB on the government web site: http://www-odi.nhtsa.dot.gov/cars/problems/defect/results.cfm You may need to click on the "document search" and then choose "TSB06-14-10 DATED 7/5/2006 ENGINE/TRANSMISSION DRIVEABILITY ISSUES" second from the last.   Also, in post 910, there is link to a flickr site. Only two of the photos are "all rights reserved", but you are able to see them and view what the PCM looks like after three years of water damage. The other photos give a good detailed shot of where the PCM is located, and some directions for correcting the problem.   Good luck. The dealership could not seem to fix our vehicle. Replies to this message: yebbie (Dec 01, 2009 10:41 am)
#939 of 946 Re: Where can you lodge a complaint? [henneberry] by mikeinpc Nov 29, 2009 (2:01 pm)
Replying to: henneberry (Nov 27, 2009 10:52 am) Looks like I am going to add myself to the growing list of people stranded by Ford. Our situation is very similar to every other posted. We were returning from visiting our son who is serving in the Military. We were traveling home on Wednesday (Thanksgiving eve) on I-10 in the Florida panhandle when suddenly our transmission quit. We were able to coast to the side of the road. We were 5 1/2 hours from our home near Tampa and had to call my father who lived in Gainesville to make a 3 1/2 hour trip to pick us up. Fortunately the small repair shop was friendly and stayed well past their closing time to wait for us to be picked up. My wife and children frequently travel to the Florida panhandle carting many youths from our church group. I am very grateful this didn't happen to them on one of those trips. I now have to deal with this remotely and then make the 10 hour round trip back to the panhandle to pick up the car and PRAY that I make it back home.   I will be contacting the NHTSB to add myself to the complaint file against Ford.
#940 of 946 Another Case of Coasting to the side by nittanylion70 Nov 30, 2009 (12:08 pm)
I too am adding myself to the list of stranded Ford owners. This past weekend I was returning from Gatlinburg and on a bridge on the 240 going around Asheville when I became a large soap box derby participant - hoping to make it across the bridge with my momentum. I was assisted by the wind of the other travelling motorists as they did their best to miss my coasting mass of helpless medal. I made it to an exit ramp and came to stop in a repair area of a shopping strip mall. We were 3 and 1/2 hours from home in unfamiliar surroundings on Thanksgiving Sunday afternoon. AAA came through with a quick tow and the driver left us off in a park where we could wait until our friends could come an get us.   Having just talked to the mechanic, the bill will be a few cents shy of $3300. Pretty close to the articles explaining this failure.   I too will be writing to Ford and to the NHTSB. Good luck all.
#941 of 946 Free???star wet PCM et al by yebbie Dec 01, 2009 (7:41 am)
greetings and hopefully some good news for fellow victims of soggy PCMs and power loss and transmissions that won't go into reverse and $1000 fixes that don't work. I too experienced all of the above, had the PCM removed and the Ford service fix for the problem installed only to get 350 miles and be stranded by the same problem. Mechanics were at a loss to figure out the source of the water infiltration and the next step was to be a new wiring harness. turns out the new repairs were more than the "trade-in" value and I was reluctant to dump it on an unsuspecting private buyer. So I figured if I was going to junk it I would just try to find the water source myself. I followed the instructions for getting to the PCM by removing the wiper arms, special puller required, about $15 at most auto stores,don't try to pry, you'll wreck the pivot arm, removing the outer cowling, couple of screws and pops off the windshield side, removed the inner cowling, 10 screws. you'll have to remove the wiper fluid lines and connector to the wiper motor to get good working room and lift off the whole assy. just take your time and don't make things worse. or give this fix to your mechanic. sounds difficult but actually only takes about 30 minutes if you have all the metric sockets. now the PCM is locate under the dash on the passenger side. there is a 40 pin connector that has a mounting bolt that you can see from the engine compartment. carefully remove that bolt and the connector will back out so you can remove it. mine had water dripping out. Its not a good thing but don't panic yet. there are 2 nuts that hold the boot cover over the PCM. you'll need a deep well socket or nut driver to remove them. 7/16 works but its 10mm metric. pull off the cover and the PCM will pull out of its bracket. my replacement had water in it too. shook it out and gently heated witha blow dryer on low. now carefully, reach inside the hole where the PCM bracket fits and feel if there is any moisture on the interior above where the PCM was installed. if it's wet I know your problem. The tubular cross member that supports the firewall is full of water. Ford uses foam like Great Stuff to fill that tube, probably for sound deadening. on my vehicle, both ends were foamed and the middle was not. I removed the clips that hold down the outer cowling and there was an inch or so of water in the tube. the clips are not water tight and the gasket on the cowling make a nice dam to hold water on the clips and over many years the tube gradually fills until its gets to the cover plate over the PCM and you get stranded.. I pulled back the insulation in the middle of the cross member. drilled a 3/8 hole at the bottom using a cordless drill to keep from being electrocuted. and watched the Ford fountain spew out. I drilled holes on both sides as well and used them as blowout holes with my compressor. water blew out everywhere. I put a small heater on the areas and after 2 days and several blowouts the chamber is dry. you'll need to dry out the PCM and connector. not too hot just drying it out low blowdryer. check the gasket around the pins on the PCM and make sure it is around all the pins. this is the seal to prevent moisture from getting into the connector. to test you can just slip the PCM in the bracket, install the boot and carefully install the connector and start the car. My trouble lights all cleared and the car ran fine. if all is good reassemble in reverse order. I purchased new clips from Ford and siliconed all them in. I thought about filling the member with foam but opted to just leave the middle hole for drainage. My thought is that the crossmember was supposed to be entirely filled with foam. There would never had been the internal leak if it was filled. I think some were and some were not would explain why we had the problem and others think the Free Star was the best car ever. Best to all. Replies to this message: shocked1 (Dec 01, 2009 5:44 pm)
#942 of 946 Re: 2005 Ford Freestar [olang] by yebbie Dec 01, 2009 (7:58 am)
Replying to: olang (Nov 09, 2009 8:51 am) Please read my recent post. It may help solve your problem.
#943 of 946 Re: Wow I can't believe it! [nonissuebs] by yebbie Dec 01, 2009 (8:59 am)
Replying to: nonissuebs (Nov 02, 2009 6:22 pm) Please read my recent post. Water in the PCM will cause all these problems. It controls every function of the engine and trans.
#944 of 946 Re: TSB 06-14-10 [nonissuebs] by yebbie Dec 01, 2009 (9:11 am)
Replying to: nonissuebs (Nov 05, 2009 5:28 pm) you are right about the water problem thought I discovered that the TSB 06-14-10 was a white wash of the actual problem I experienced. see my recent post on my real fix.
#945 of 946 Re: resealling pcm 2004 monterey [nadineb] by yebbie Dec 01, 2009 (10:41 am)
Replying to: nadineb (Nov 29, 2009 10:31 am) Hi, new to forum. posted my observations and fix on my 2005 freestar. could this info be useful in pursuit of recall? I found the Ford fix to be ineffective and got water in anyway. I think the infiltration is from inside as a result of poor quality control when insulating the cross member.
#946 of 946 Re: Free???star wet PCM et al [yebbie] by shocked1 Dec 01, 2009 (5:44 pm)
Replying to: yebbie (Dec 01, 2009 7:41 am) My problem with my "Free Junk" is totally different. They say trannsmission was made too small for engine . And the Torque Convertor breaks & "blows up" the plantarium. I, as the rest, had NOOOO warning of tranny not pulling. Just came off 270 in ohio. God was with us, all I can say. SO, COME ON FORD OWN UP & HAVE A RECALL ON THESE DEATH TRAPS!!!!!!!!!! We can't EVEN take Grand kids in this crap to see Christmas lights!!!!

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