My car has spent 10 days at Ford to be serviced after having the safety recall service for the torque converter performed. The vehicle was behaving unpredictably, sometimes stalling out while idled, stalling out while in motion, sometimes idling with high or low rpms. The dealership took it back in to check the torque converter, they then said it wasn't the torque converter but the throttle body, they then cleaned that and said it's not the throttle body, it's the PCM. The PCM is taking on water from a flawed design of the above PCM where water is retained and eventually leaks on to the connector. This of course is not covered by Ford, and can cost up to $1200 to replace. This issue creates a number of different symptoms making it hard to identify the origin of the problem. Causing extended stays for maintenance. This should be rectified by Ford and not it's customers as there's no way this flaw can be caused by user error, it's a design flaw that should not exist.

- Bayonne, NJ, USA

2nd time that this has happened. Was driving when the van started bucking/sputtering/surging. It would die and then fire right back up just to do it once again. Soaked PCM connector was to blame both times. This is obviously a design flaw by Ford and needs to be taken care of. I'm glad I was not on the interstate or in the middle of an intersection.

- Jetersville, VA, USA

I was driving the vehicle and it was raining outside and as I was driving all of a sudden my car just died in the middle of the freeway no warning, no nothing just died I almost was rear ended, I took it to a mechanic who said the PCM is not sealed properly and got wet and fried out this is unbelievable that Ford would see tons of these complaints like I have seen online same problems and put people lives and their children's lives in danger with this poor manufacturing. What can I do "?" thank you [xxx] VIN unavailable information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- San Bernardino, CA, USA

Started sputtering, jerking, and stalling PCM was wet causing all kinds of havic lost power going into a turn and almost went into a ditch Ford needs to recall this ongoing problem and get it fixed before something major happens alot of people are complaining and Ford knows it is there fault and they have a problem but refuses to take care of it.

- Albion, IN, USA

The contact owns a 2004 Ford Freestar. While driving approximately 30 mph, the accelerator pedal was applied and there was no engine power. The vehicle was towed to the contact's residence. In 2013, the vehicle was repaired under NHTSA campaign number: 12V006000 (power train), but the failure recurred recently because the remedy was insufficient. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 162,801.

- Wheatfield, IN, USA

Turns out there was a recall on the 2004 Ford Freestar in 2012 regarding the torque converter. Here it is two years later and it goes out again. This should not happen. There needs to be another recall on the torque converter and it needs to be fixed properly this time before there is a death from the incident. I had two kids under the age of 3 with me at the time and sitting in the pouring rain, in chilly weather, waiting for a ride home was not fun. Fix it Ford!!!

- Virginia Beach, VA, USA

The contact owns a 2004 Ford Freestar. The contact stated that while driving at 70 mph, the engine stalled. The failure occurred several times. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The VIN was not available. The approximate failure mileage was 150,000.

- Center Valley , PA, USA

After a rain van stalled in the middle of heavy traffic and would not restart.after several hours van would not start.I had van towed to a repair shop, PCM was replaced.@present headlights not working properly, air conditioning, horn, seat belt chimes not working at all.local dealership unable to repair.van continues to run rough.

- Prichard, AL, USA

. in addition to causing an engine to stall, which may or may not then restart, transmission shift poorly, the vehicle has had erratic power, almost every time there is an inability to shift the vehicle into either forward or reverse. On start up no matter the temp of vehicle the idle RPM is higher than normal in park ! it has been service many many times.. now our transmission fluid looks like pepto bismol !!

- Lima, OH, USA

I just purchased a 2004 Ford Freestar from a private seller and I was getting the vehicle ready for inspection and subsequently tag by replacing front and rear brakes, tie end rod and tires. On highway 495 heading back to mechanic shop, the engine cutting off without warning and vehicle stalled and engine stopped running on lane next to fastest lane and many vehicles behind me kept blowing horns and missed hitting me at last minute as this happened suddenly on busiest highway. End of report.

- Bowie, MD, USA

Car history: The transaxle light has gone before when we travel through vt mountains, but turning off the engine and letting it sit, and restarting it, the light would go off. Upon getting home safety, our mechanics didn't find anything to repair and so left it be, and would only sometimes see it when we traveled through the vt mountains, a few times a year. All recall repairs were up to date. There were no other symptoms. Incident: As we nearing the top of a mountain, the transaxle light came on. Unlike the other times, the transmission suddenly failed to be in the correct gear, so unlike the other times, we were very concerned. We pulled over immediately, and as we reached the shoulder smoke began pouring out of the vents. We quickly evacuated our kids, and as we were getting them out we noticed that there was already fire coming from under the hood, near the windshield, on the passenger side. We are so glad our kids were awake, and able to unlatch their own child carseats, and able to get out quickly. The fire spread to the entire van, consuming everything, at a great expense to us. (and others; our accident blocked a significant amount of traffic for about 3 hours.)

- Barrington, NH, USA

The contact owns a 2004 Ford Freestar. The contact stated while driving 70 mph, the check engine and trans axle lights illuminated on the instrument panel. Immediately after, the vehicle stalled and was not able to be restarted. The vehicle was towed to an independent mechanic. The technician was unable to diagnose the failure. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was unknown.

- Eight Mile , AL, USA

In good weather without warning the engine stalled in traffic. Restarted, but the engine ran extremely rough. Also the transmission would not go into reverse. Managed to get to a independent service shop. There the technician found water in the PCM. Dried out PCM and car ran fine. Then the transmission light came on. Now they found water in the transmission connector. Two weeks later the car would often not start, and when it did the transmission would not shift out of first gear. On our third visit they replaced the throttle position sensor (tps). One week later same symptoms, this time tps and mass airflow sensors have failed. The problems are all related to the wet PCM! recall this car, now!!!!!

- South Lyon, MI, USA

First time;while driving around a curve going approximately 40 miles per hour, the engine shut off, and lost power, and steering. Engine light came on 2nd time; engine bucked at about 40 miles to 50 miles per hour, then the engine shut off, and lost power and steering. Engine light came on 3rd time; same as the second time, engine light came on. Went to a mechanic who stated that ran the engine on computer, and the code:PO741 came up, tcc clutch performance. Was told to go to Ford for this because of current recall. Went online to Ford, and our VIN came up for torque converter replacement. Awaiting appointment on Tuesday, June 3rd. At Ford dealer.

- Hillsborough, NJ, USA

While driving the motor stalls, twice is cut off, the other 2 times is sputtered and jerked but finally started back to normal. Almost got hit twice because of motor stalling. Our charity (www.donatecca.org) bought the car in Feb 2014, since then there has been a loud gurgling sound coming from the dash board, never stops. Car does not overheat at all.

- Lancaster, PA, USA

Problems with engine since 2005 with jerking, sputtering, engine lockup. Transmission locks and jerks, airconditioner stopped cooling and won't hold freon. Electrical issues also......has a mind of its own! several trip to the Ford dealership, was told "could not diagnose, bring it back if it does it again, we can't find anything wrong with it". the issues are sporadic. Drives fine one minute, next thing you know you are stalled on busy hwy. Not enough space to list "expensive" problems. Extended warranty? that's a joke, waste of $. scariest issue is when it locked up while driving. Lost complete control of steering, acceleration, etc. Was stranded in middle of road. Have disability, very scary & frustrating especially since my husband bought it only a year old so kids and I would have a "safe" vehicle. Did not take back to dealership since they'd probably say " can't diagnose". purchased a rebuilt engine had small town mechanic put it in. Problems still going on. Since there are still so many problems with engine, transmission, electrical, and no air conditioning, I'm afraid to drive it more than 5 miles. It is a very expensive lawn ornament. Fyi, my husband had just had to replace the engine in his Ford vehicle a month before mine went out, had to sell his vacation time for 2 years in a row just to keep those Ford running for our family...he's a public safety officer. Ford sold be ashamed. (dates are approximate, paperwork packed up from a move....sorry:-) )

- Wetumpka, AL, USA

In November of 2013, our 2004 Ford Freestar quit working. Yes, we had the torque converter recalled and put on back when they had that recall. November was the first time we had this happen to our car. It was raining, and our car would not go into gear, it quit working. What made this bad is that it was on the freeway! my husband put it into neutral, but we still did not have steering capabilities and managed to get us over to the shoulder. We had to be towed to a dealership. The dealership then stated that many people were having the same issue with the electronics getting wet, so he dried it, then let it set for a couple days and caulked it. We thought that would end those problems. Not. (note: This had cost us 450.00) then less than 2 months, the same exact thing happens, only this time we are stuck in a shopping center and could not get our car into gear again. We took it back to the dealership to which they replied that we needed a new electric module. How much" $1500!!! in less than 2 months, we spent almost 2,000.00! this was done in February. Here it is now April and guess what" the same exact problem is taking place again!! we are not alone, there are many people facing the same problems we have had, look around at the boards online and you will see that everyone has the same issues!! some investigations need to be opened or reopened as this is not resolved and lawsuits will be filed if someone gets hurt.

- Gig Harbor, WA, USA

The contact owns a 2004 Ford Freestar. The contact was driving 40 mph when the vehicle suddenly stalled. The vehicle was restarted and performed normally. The vehicle was not taken to a dealer or an independent mechanic for inspection. The manufacturer was made aware of the issue. The approximate failure mileage was 80,000.

- Philadelphia, PA, USA

Purchased used vehicle from marshall used cars in sacramento, ca, where reside currently. Purchased 05/2011, paid full no loan at time of purchase. Purchased add. Ext. Warranty which was 6months. From the dos til present date; I have paid, and was mislead in all the insurance covering major defects, owner(me) had came out of pocket paying for service to fix warranty parts. Now this is the current and serious issue. I am disabled, I have a disable child. My vehicle was reported under VIN to Ford corporate to notate for service to be check and worked on at local Ford dealer. Complained about multiple (4) issues. Dealership mislead me, and did not perform work. Only work they did was replace 1 recall 10/12. After recall service I (owner) recall manufac. Made claim, again and then went to dealer. I was turned away...and told to do normal maintenance before putting a service claim in. This is a problem. I am not ignorant to the anatomy of a vehicle. I am very literate on understanding vehicle operations as well as maintaining maintenance. I can say this because I believe I should be aware of every issue so I wont have a disabled vehicle. Vehicle mileage applied from the date recall replaced 5800 within the time til I made another claim in Oct 2013. Took vehicle in, told to check everything. Did. Brought vehicle back and vehicle was in service dept for week which rolled over to Nov 1, 2013. Vehicle was dx and found to be the same thing I made a claim about. Vehicle has a defected recall part. Part was not replaced. And owner is now left with a defect recall part, plus more damage on other parts related to torque converter, fuel line, 3rd bench, front R-wheel hub. I have multiple health appts to maintain for me and my child's disability. My children need to get to school, and I missed legal appt dates from court.

- Sacramento, CA, USA

Driving South on I 75, returning from a week's vacation, in medium Saturday traffic the car started to act up. Lights, warning lights, gauges, even the temperature and compass started flashing and going on and off. There was an exit a mile ahead when the engine died, right in front of a semi. I had to swerve to the side of the road to narrowly avoid an accident. The car would not start after that. I had to arrange a tow and was left stranded for five days. The Ford dealer up North could not get the part for three weeks. Now it's at a Ford dealer here, by detroit, for over a week. They said it will cost over one thousand dollars to replace the PCM. Looking on line I see all the complaints and repairs reported about this car, and you are doing nothing"? after seeing the PCM and the repairs to fix the problem you have to wonder why the brain of the car is in a spot where it can get wet, and why there are holes in the top to let water in? how many problems, accidents, or deaths do there have to be to start a recall???"

- Warren, MI, USA