FORD Freestar 2004 User Manual v.2

The following information is specifically for the Freestar cargo van only; it is in addition to the existing information found on pages 200, 201, 207 and 208.

Location of the spare tire and tools

Item Location

Jack extension tool Attached to the jack kit.

Removing the spare tire

1. Lift flap in mat to expose hex nut. Insert extension tool through access hole and engage hex nut. Place lug wrench onto end of extension tool.

Stowing the full-size tire

1. Remove the perforated section of the vinyl mat in the center floor area in order to install the wing screw.

2. Using the tether cable kit located with the jack, pass the cable retainer through the center of the wheel.

3. Lay the tire flat and secure the cable with wing screw by installing it on the wing screw retainer in the floor and turning the wing screw clockwise. You will hear an audible click when the tire is properly secured.

Stowing the spare tire

3. Raise the tire by turning the jack extension tool clockwise with the lug nut wrench until the hex nut ratchets.

Table of Contents

Introduction 4 Instrument Cluster 10

Warning and control lights 10 Gauges 16

Entertainment Systems 19

AM/FM stereo 19 AM/FM stereo with CD 21 AM/FM stereo with in-dash six CD 24 AM/FM stereo cassette with CD 27

Climate Controls 34

Manual heating and air conditioning 34 Rear window defroster 43

Lights 44

Headlamps 44 Turn signal control 48 Bulb replacement 50

Driver Controls 55

Windshield wiper/washer control 55 Steering wheel adjustment 56 Power windows 66 Mirrors 67 Speed control 69 Message center 77

Table of Contents

Locks and Security 89

Keys 89 Locks 89 Anti-theft system 91

Seating and Safety Restraints 104

Seating 104 Safety restraints 127 Air bags 141 Child restraints 153

Driving 167

Starting 167 Brakes 171 Transmission operation 175 Vehicle loading 180 Trailer towing 184 Recreational towing 187

Roadside Emergencies 189

Getting roadside assistance 189 Hazard flasher switch 190 Fuel pump shut-off switch 190 Fuses and relays 191 Changing tires 199 Jump starting 209 Wrecker towing 215

Customer Assistance 216

Reporting safety defects (U.S. only) 224

Table of Contents

Cleaning 225 Maintenance and Specifications 231

Engine compartment 233 Engine oil 234 Battery 237 Fuel information 244 Low tire warning system 257 Tire Information 260 Part numbers 272 Refill capacities 273 Lubricant specifications 274

Accessories 281 Index 283

All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

Introduction

CALIFORNIA Proposition 65 Warning

WARNING: Engine exhaust, some of its constituents, and

certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

CONGRATULATIONS

Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle, the greater the safety and pleasure you will derive from driving it.

For more information on Ford Motor Company and its products visit the following website:

• In the United States: www.ford.com

• In Canada: www.ford.ca

• In Australia: www.ford.com.au

• In Mexico: www.ford.com.mx

Additional owner information is given in separate publications. This Owner’s Guide describes every option and model variant available

and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available.

Remember to pass on this Owner’s Guide when reselling the vehicle. It is an integral part of the vehicle.

Fuel pump shut-off switch: In the event of an accident the

safety switch will automatically cut off the fuel supply to the engine. The switch can also be activated through sudden vibration (e.g. collision when parking). To reset the switch, refer to the Fuel pump shut-off switch in the Roadside Emergencies chapter.

Introduction

SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed.

Warning symbols on your vehicle

When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind.

Protecting the environment

We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste, cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.

BREAKING-IN YOUR VEHICLE

Your vehicle does not need an extensive break-in. Try not to drive continuously at the same speed for the first 1,600 km (1,000 miles) of new vehicle operation. Vary your speed to allow parts to adjust themselves to other parts.

Drive your new vehicle at least 800 km (500 miles) before towing a trailer.

Do not add friction modifier compounds or special break-in oils during the first few thousand kilometers (miles) of operation, since these additives may prevent piston ring seating. See Engine oil in the Maintenance and Specifications chapter for more information on oil usage.

Introduction

SPECIAL NOTICES Emission warranty

The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 6.0L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

Service Data Recording

Service data recorders in your vehicle are capable of collecting and storing diagnostic information about your vehicle. This potentially includes information about the performance or status of various systems and modules in the vehicle, such as engine, throttle, steering or brake systems. In order to properly diagnose and service your vehicle, Ford Motor Company, Ford of Canada, and service and repair facilities may access vehicle diagnostic information through a direct connection to your vehicle when diagnosing or servicing your vehicle.

Event Data Recording

Other modules in your vehicle — event data recorders — are capable of collecting and storing data during a crash or near crash event. The recorded information may assist in the investigation of such an event. The modules may record information about both the vehicle and the occupants, potentially including information such as:

• how various systems in your vehicle were operating;

• whether or not the driver and passenger seatbelts were buckled;

• how far (if at all) the driver was depressing the accelerator and/or the

brake pedal;

• how fast the vehicle was traveling; and

• where the driver was positioning the steering wheel.

To access this information, special equipment must be directly connected to the recording modules. Ford Motor Company and Ford of Canada do not access event data recorder information without obtaining consent, unless pursuant to court order or where required by law enforcement, other government authorities or other third parties acting with lawful authority. Other parties may seek to access the information independently of Ford Motor Company and Ford of Canada.

Introduction

Special instructions

For your added safety, your vehicle is fitted with sophisticated electronic controls.

Please read the section Supplemental restraint system (SRS)

in the Seating and Safety Restraints chapter. Failure to follow the specific warnings and instructions could result in personal injury.

Front seat mounted rear-facing child or infant seats should

NEVER be placed in front of an active passenger air bag.

MIDDLE EAST/NORTH AFRICA VEHICLE SPECIFIC INFORMATION

For your particular global region, your vehicle may be equipped with features and options that are different from the ones that are described in this Owner’s Guide; therefore, a supplement has been supplied that complements this book. By referring to the pages in the provided supplement, you can properly identify those features, recommendations and specifications that are unique to your vehicle. Refer to this

Owner’s Guide for all other required information and warnings.

Introduction

These are some of the symbols you may see on your vehicle.

Vehicle Symbol Glossary

Safety Alert

Fasten Safety Belt Air Bag-Front

Air Bag-Side Child Seat

Child Seat Installation Warning

Child Seat Tether Anchor

Anti-Lock Brake System

Traction Control AdvanceTracy

Master Lighting Switch Hazard Warning Flasher

Fog Lamps-Front Fuse Compartment

See Owner’s Guide

Child Seat Lower Anchor

Brake System

Brake Fluid Non-Petroleum Based

Fuel Pump Reset Windshield Wash/Wipe

Windshield Defrost/Demist

Rear Window Defrost/Demist

Vehicle Symbol Glossary

Introduction

Power Windows Front/Rear

Child Safety Door Lock/Unlock

Power Window Lockout

Interior Luggage Compartment Release Symbol

Panic Alarm Engine Oil

Engine Coolant

Engine Coolant Temperature

Do Not Open When Hot Battery

Avoid Smoking, Flames, or Sparks

Battery Acid

Explosive Gas Fan Warning

Power Steering Fluid

Maintain Correct Fluid Level

Emission System Engine Air Filter

MAX

MIN

Passenger Compartment Air Filter

Jack

Check fuel cap Low tire warning

Instrument Cluster

WARNING LIGHTS AND CHIMES

Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause extensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works. If any light remains on after starting the vehicle, have the respective system inspected immediately.

Check engine: The Check Engine indicator light illuminates when the ignition is first turned to the ON position to check the bulb. Solid illumination after the engine is started indicates the On Board Diagnostics System (OBD-II) has detected a malfunction. Refer to On board diagnostics (OBD-II) in the Maintenance and Specifications chapter. If the light is blinking, engine misfire is occurring which could damage your catalytic converter. Drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced immediately.

Under engine misfire conditions, excessive exhaust temperatures

could damage the catalytic converter, the fuel system, interior floor coverings or other vehicle components, possibly causing a fire.

Instrument Cluster

Check fuel cap: Illuminates when the fuel cap may not be properly installed. Continued driving with this light on may cause the Check engine warning light to come on, refer to Fuel filler cap in the Maintenance and Specification chapter.

Brake system warning light: To confirm the brake system warning light is functional, it will momentarily illuminate when the ignition is turned to the ON position when the engine is not running, or in a position between ON and START, or by applying the parking brake when the ignition is turned to the ON position. If the brake system warning light does not illuminate at this time, seek service immediately from your dealership. Illumination after releasing the parking brake indicates low brake fluid level and the brake system should be inspected immediately by your servicing dealership.

Driving a vehicle with the brake system warning light on is

dangerous. A significant decrease in braking performance may occur. It will take you longer to stop the vehicle. Have the vehicle checked by your dealer immediately.

Anti-lock brake system: If the ABS light stays illuminated or continues to flash, a malfunction has been detected, have the system serviced immediately. Normal braking is still functional unless the brake warning light also is illuminated.

Air bag readiness: If this light fails to illuminate when ignition is turned to ON, continues to flash or remains on, have the system serviced immediately. A chime will also sound when a malfunction in the supplemental restraint system has been detected.

ABS

Instrument Cluster

Safety belt: Reminds you to fasten your safety belt. A chime will also sound to remind you to fasten your safety belt.

Check transaxle: Illuminates when a transaxle problem has been detected and shifting may be restricted. If the light remains on, have the system serviced immediately.

Charging system: Illuminates when the battery is not charging properly.

Engine oil pressure: Illuminates when the oil pressure falls below the normal range, refer to Engine oil in the Maintenance and specifications chapter.

Engine coolant temperature: Illuminates when the engine coolant temperature is high. Stop the vehicle as soon as possible, switch off the engine and let cool. Refer to Engine coolant in the Maintenance and specifications chapter.

• Without Message Center

• With Message Center

Never remove the coolant

recovery cap while the engine is running or hot.

Instrument Cluster

Traction Controly or AdvanceTracy active (if equipped):

Illuminates when the Traction Controly is active, refer to the Driving chapter for more information.

• Without Message Center

• With Message Center

TRAC

ACTIVE

Traction Controly or AdvanceTracy off light (if equipped): Illuminates when the

Traction Controly has been disabled (by the driver or as a result of a system failure). Refer to the Driving chapter for more information.

Low tire warning: Illuminates when the low tire warning system is enabled. If the light remains on while driving, the tire pressure should be checked, refer to Low tire warning in the Maintenance and Specifications chapter.

Low fuel: Illuminates when the fuel level in the fuel tank is at or near empty (refer to Fuel gauge in this chapter).

Speed control: Illuminates when the speed control is engaged. Turns off when the speed control system is disengaged.

TRAC

OFF

Instrument Cluster

Low washer fluid: Illuminates when the windshield washer fluid is low.

• Without Message Center

• With Message Center

Door ajar: Illuminates when the ignition is in the ON position and any door is open.

• Without Message Center

• With Message Center

Displays which door or the liftgate is open.

Turn signal: Illuminates when the left or right turn signal or the hazard lights are turned on. If the indicators stay on or flash faster, check for a burned out bulb.

Instrument Cluster

Bulb warning: Illuminates when one of the exterior front turn lamps or rear brake/turn/tail lamps bulb has burned out.

• Without Message Center

• With Message Center

Displays which bulb is burned out. Depress the RESET control to clear.

High beams: Illuminates when the high beam headlamps are turned on.

Key-in-ignition warning chime: Sounds when the key is left in the ignition in the OFF/LOCK or ACCESSORY position and the driver’s door is opened.

Headlamps on warning chime: Sounds when the headlamps or parking lamps are on, the ignition is off (the key is not in the ignition) and the driver’s door is opened.

Turn signal warning chime: Sounds when the turn signal lever has been activated to signal a turn and not turned off after the vehicle is driven more than 0.8 km (1/2 mile).

Instrument Cluster

GAUGES

Speedometer: Indicates the current vehicle speed.

Engine coolant temperature gauge: Indicates engine coolant

temperature. At normal operating temperature, the needle will be in the normal range (between “H” and “C”). If it enters the red section,

the engine is overheating. Stop the vehicle as soon as safely possible, switch off the engine and let the engine cool.

Never remove the coolant reservoir cap while the engine is

running or hot.

Instrument Cluster

Odometer: Registers the total kilometers (miles) of the vehicle.

• Without Message Center To switch the display from Metric to

English, press and hold the button on the cluster for three seconds. The temperature display in the overhead console (if equipped) will also be changed.

• With Message Center Refer to Message Center in the

Drivers Controls chapter on how to switch the display from Metric to English.

Trip odometer: Registers the kilometers (miles) of individual journeys.

• Without Message Center Press and release the button on the

cluster to toggle between odometer and trip odometer display. To reset, press the button again until the trip reading is 000000.0 miles.

• With Message Center To reset, press and hold the

message center RESET button for three seconds to reset.

Tachometer: Indicates the engine speed in revolutions per minute. Driving with your tachometer pointer continuously at the top of the scale may damage the engine.

Instrument Cluster

Fuel gauge: Indicates approximately how much fuel is left in the fuel tank (when the ignition is in the ON position). The fuel gauge may vary slightly when the vehicle is in motion or on a grade.

The arrow near the fuel pump icon indicates which side of the vehicle the fuel filler door is located.

Refer to Filling the tank in the Maintenance and Specifications chapter for more information.

Entertainment Systems

AM/FM STEREO SYSTEM (IF EQUIPPED)

Entertainment Systems

/ Tuner: Press to

1. manually go up or down the radio

frequency. Also use in menu mode to select various settings.

2. Audio: Press to access select various settings.

Treble: Press to adjust the treble setting. Use SEEK

Bass: Press to adjust the bass setting. Use SEEK

Balance: Press to adjust the audio between the left and right speakers. Use / / SEEK, SEEK .

Fade: Press to adjust the audio between the front and rear speakers. Use

/ / SEEK, SEEK .

/ / SEEK,

Entertainment Systems

3. Seek: Press to access the next/previous strong station or track.

4. Memory presets: To set a station: Select frequency band AM/FM; tune to a station, press and hold a preset button until sound returns.

5. AM/FM: Press to select AM/FM frequency band.

6. ON/OFF/Volume: Press to turn ON/OFF. Turn to increase/decrease volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

7. CLK (Clock): Press to toggle between the clock and radio display. To set the clock: Press and hold CLK until the hours begin to flash.

Press again to set the minutes.

When this audio is used in cargo vans where no rear speakers are installed in the vehicle, fading to the rear speakers will result in no audio output.

/ to manually decrease / increase the hours. Press CLK

Entertainment Systems

AM/FM STEREO/ SINGLE CD SOUND SYSTEM (IF EQUIPPED)

/ Tuner: Press to

1. manually go up or down the radio

frequency. Also use in menu mode to select various settings.

2. Phone/mute: Press to mute the playing media. Press again to return to the playing media.

3. Menu: Press to toggle through the following modes:

Treble: Press to adjust the treble setting. Use

Bass: Press to adjust the bass setting. Use

Balance: Press to adjust the audio between the left and right speakers.

Use

/ / SEEK .

Entertainment Systems

Fade: Press to adjust the audio between the front and rear speakers. Use

Speed sensitive volume (if equipped): Radio volume automatically changes slightly with vehicle speed to compensate for road and wind

noise. Press MENU to access and use

Setting the clock: Press MENU until SELECT HOUR or SELECT MINUTE is displayed. Use MENU again to disengage clock mode.

If your vehicle is equipped with an in-dash clock, refer to “Setting the clock” in the Driver Controls chapter.

Autoset: Allows you to set the strongest local radio stations without losing your original manually set preset stations for AM/FM1/FM2 . Press

MENU to access. Use When the six strongest stations are filled, the station stored in preset 1

will begin playing. If there are less than six strong stations, the system will store the last one in the remaining presets.

4. Aux: Press to toggle between FES/DVD and AUX modes. If no auxiliary sources are available, NO AUX AUDIO will be displayed.

5. Seek: Press to access the next strong station or track.

/ / SEEK .

/ / SEEK to adjust.

/ to manually increase/decrease Press

/ / SEEK to set.

6. Text: In CD mode, this feature reads track name, artist name, and disc name (if available).

7. Shuffle: Press to play tracks in random order.

8. Comp (Compression): In CD mode, brings soft and loud CD passages together for a more consistent listening level.

9. Repeat: Press to repeat the current CD track.

Entertainment Systems

10. Fast forward: Press to manually advance in a CD track.

11. Rewind: Press to manually reverse in a CD track.

12. Memory presets: To set a station: Select frequency band AM/FM; tune to a station, press and hold a preset button until sound returns.

13. Scan: Press for a brief sampling of radio stations or CD tracks. Press again to stop.

14. Seek: Press to access the previous strong station or track.

15. AM/FM: Press to select AM/FM frequency band.

16. ON/OFF/Volume: Press to turn ON/OFF. Turn to increase/decrease volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

17. CD: Press to enter CD mode. If a CD is already loaded into the system, CD play will begin where it ended last.

18. CD eject: Press to eject a CD.

19. CD slot: Insert a CD label side up.

Entertainment Systems

PREMIUM IN-DASH SIX CD SOUND SYSTEM (IF EQUIPPED)

/ Tuner: Press to

1. manually go up or down the radio

frequency. Also use in menu mode to select various settings.

2. Phone/mute: Press to mute the playing media. Press again to return to the playing media.

3. Menu: Press to toggle through the following modes:

Treble: Press to adjust the treble setting. Use

Bass: Press to adjust the bass setting. Use Balance: Press to adjust the audio between the left and right speakers.

Use

Fade: Press to adjust the audio between the front and rear speakers. Use

/ / SEEK .

Entertainment Systems

Speed sensitive volume (if equipped): Radio volume automatically changes slightly with vehicle speed to compensate for road and wind

noise. Press MENU to access and use / / SEEK to adjust.

Setting the clock: Press MENU until SELECT HOUR or SELECT MINUTE is displayed. Press hours/minutes. If your vehicle is equipped with an in-dash clock, refer to “Setting the

clock” in the Driver Controls chapter. Autoset: Allows you to set the strongest local radio stations without

losing your original manually set preset stations for AM/FM1/FM2 . Press MENU to access. Use When the six strongest stations are filled, the station stored in preset 1

will begin playing. If there are less than six strong stations, the system will store the last one in the remaining presets.

4. Aux: Press to toggle between FES/DVD and AUX modes. If no auxiliary sources are available, NO AUX AUDIO will be displayed.

5. Seek: Press to access the next strong station or track.

/ / SEEK to adjust the

/ / SEEK to set.

6. Text: In CD mode, press to display the track name, artist name and disc name (if available).

7. Shuffle: Press to play tracks in random order.

8. Comp (Compression): In CD mode, brings soft and loud CD passages together for a more consistent listening level.

9. Repeat: Press to repeat the current CD track.

Entertainment Systems

10. Fast forward: Press to manually advance in a CD track.

11. Rewind: Press to manually reverse in a CD track.

12. Memory presets: To set a station: Select frequency band AM/FM; tune to a station, press and hold a preset button until sound returns.

13. Scan: Press for a brief sampling of radio stations or CD tracks. Press again to stop.

14. Seek: Press to access the previous strong station or track.

15. AM/FM: Press to select AM/FM frequency band.

17. CD: Press to enter CD mode. If a CD is already loaded into the system, CD play will begin where it ended last.

18. LOAD: Press to load a CD, then select a slot number using the radio presets 1 through 6. If you don’t select a slot within 5 seconds, the radio shall choose the first available slot for you. Press and hold for 2 seconds to auto load up to six CDs.

19. CD eject: Press to eject a CD, then select the desired CD slot using the radio presets 1 through 6.

Entertainment Systems

If a slot is not selected within 5 seconds, the radio shall eject the current disc. Press and hold for 2 seconds to auto eject all CDs present in the radio mechanism.

20. CD slot: Insert a CD label side up.

AM/FM STEREO CASSETTE/SINGLE CD SOUND SYSTEM (IF EQUIPPED)

/ Tuner: Press to

1. manually go up or down the radio

frequency. Also use in menu mode to select various settings.

2. Seek: Press to access the next strong station or track.

3. Phone/mute: Press to mute the playing media. Press again to return to the playing media.

Entertainment Systems

4. Menu: Press to toggle through the following modes:

Treble: Press to adjust the treble setting. Use

Bass: Press to adjust the bass setting. Use

Balance: Press to adjust the audio between the left and right speakers.

Use

Fade: Press to adjust the audio between the front and rear speakers. Use

Speed sensitive volume (if equipped): Radio volume automatically changes slightly with vehicle speed to compensate for road and wind

noise. Press MENU to access and use

Setting the clock: Press MENU until SELECT HOUR or SELECT MINUTE is displayed. Press hours/minutes. If your vehicle is equipped with an in-dash clock, refer to “Setting the

clock” in the Driver Controls chapter. Autoset: Allows you to set the strongest local radio stations without

losing your original manually set preset stations for AM/FM1/FM2 . Press MENU to access. Use When the six strongest stations are filled, the station stored in preset 1

will begin playing. If there are less than six strong stations, the system will store the last one in the remaining presets.

Clean tape reminder: After 20 hours of cassette operation, the radio will notify you that it is time to clean the cassette player head. After cleaning the player head, you can clear the reminder through menu control and selecting YES.

/ / SEEK .

/ / SEEK to adjust.

/ / SEEK to adjust the

/ / SEEK to set.

/ / SEEK .

Entertainment Systems

5. AUX: Press to toggle between FES/DVD and AUX modes. If no auxiliary sources are available, NO AUX AUDIO will be displayed. To return to radio mode, press AM/FM.

6. Tape eject: Press to eject a tape.

7. Text: In CD mode, displays track title, artist name, and disc title (if available).

8. Shuffle: Press to play CD tracks in random order.

9. Compress (Compression): In CD mode, brings soft and loud CD passages together for a more consistent listening level.

10. Repeat: Press to repeat the current CD track.

11. Fast forward: Press to manually advance in a CD track or cassette.

12. Rewind: Press to manually reverse in a CD track or cassette.

13. Memory presets: To set a station: Select frequency band AM/FM; tune to a station, press and hold a preset button until sound returns.

14. Tape: Insert a tape facing to the right.

15. Tape direction: Press to enter tape mode. Press while in play mode to change which side of the tape is playing.

+ 259 hidden pages

FORD Freestar 2004 User Manual v.2

Specifications and Main Features

Frequently Asked Questions

User Manual