Howdy, Stranger!

It looks like you're new here. If you want to get involved, click one of these buttons!

Ford Freestar/Mercury Monterey



  • veepee1veepee1 Posts: 6
    My 2004 Monterey with 72K was diagnosed with OBD code PO401, This code referred to the EGR valve, or the DPFE sensor may be defective. I removed the EGR valve and there was no indication of carbon deposit. I was informed that the DPFE sensor was in the rear of the engine which is not easily visible. My question is how do I gain access to this unit, and what checks do i make to determine that it is defective. Your suggestion will be appreciated.
  • skibowskibow Posts: 1
    do you have any paint peeling problems, looking for anyone with 2005 Freestar with paint peeling off like a laminate
  • I had the same OBD code on my 2004 Mercury Monterey. I replaced the EGR valve, at a cost of less than $50. I am no mechanic, but it took me less than 30 minutes to replace. It has been about a month, and the engine light has not come one again since the EGR valve was replaced.
  • veepee1veepee1 Posts: 6
    My 2004 Monterey with 82k has recently began jerking or bucking when moving off, or under load travelling up to 40- 45mph. It runs smoothly when cruising. I changed the gas filter recently as I suspect that it could be fuel related, but it made no difference. It also idles a bit irregular. Does anyone have an idea or suggestion as what possible could be causing this problem, or what to check for. Your input will be appreciated.
  • Where did you find the EGR for $50? I have been searching and I can't find one that cheap, I would love to though. Can you send me the link. Thanks
  • I've got the same problem. I did have the P401 code flash. Found the part on amazon using the motorcraft pn from rockauto. cheap about $75. That didn't fully fix the issue but I've noticed that since it has gotten colder it doesn't happen as much but still does. Any progress? Has anyone had this issue and a transaxle change fixed the problem?
  • I should have been clearer on my problem. i have the same issue with my van jerking at 45 mph under load in 4th gear at low rpms before upshifting.

    I also have the driver seat heated seats not working. I see both problems in these posts. Has anyone actually fixed either?
  • fdbgtfdbgt Posts: 1
    Had the same problem.....replaced the EGR valve, replaced the coil and wires and spark plugs, no real difference.

    I now believe that moisture got into the PCM connector and once it dried out, the problem went away...see this link for a detailed description (its a pdf doc.)

    link title
  • philvidphilvid Posts: 8
    I agree, we need to get together and fight Ford. The problem is I'm in Canada so we don't have the same laws...

  • zan9zan9 Posts: 1
    I had the same problem. It would jerk at around 45 mph. I took it in, and there was a cracked vacuum hose plastic part thing, and they replaced a coil head and spark plugs. it all came to around $1200 with labor at a Ford dealership. Since I know nothing about cars, I had to pay it. It did make the jerking go away.
    I just feel the van isn't running smooth. The idle sound is so loud, like a truck.

    My driver side heated seat also died. When under warranty. They "couldn't" fix it, or so they said.

    I'm at 91000, and I hope to be able to drive a few more years. I'm still paying on it! blech!
  • I am experiencing similar problems, Jerking under load at about 40mph. The CIL came on after. Diagnosis revealed the above codes. What is the easiest way to get to the No. 1 cyl. and what could be the possible cause for a misfire.
  • dlshnndlshnn Posts: 2
    edited September 2011
    Not sure what is going on with my Monterey. It is a well cared for 2004 that all of a sudden started to have a little shake when accelerating. Once I got up past 50-55ish it almost went away. I assumed I had a wheel out of balance so when I had it in for an oil change a few days later, I had them do a rotation and balance. That really didn't fix anything and it got worse. If I was accelerating up hill(which I have to do a lot since I live at the bottom of a hill) then it was like I was driving over hundreds of broomsticks that someone had lay across the road. I took it to a shop (not my usual one, but it was very close to home) to see what they thought. They looked and said CV shaft. When I was able to get it into my regular shop, they looked at it and said 'Found transaxle output shaft bearing on right side axle very loose causing excessive movement with right axle.' He said the right axle was basically loose where it attached to the transmission. They said they would have to research if it was actually a bushing or a bearing in order to tell me the repair cost. Monday morning I get a call saying basically I need a new transmission. Now the vibration isn't as bad, but is still there. It also feels like it is wanting to take off while I am driving at a constant speed. Not chugging out, but like all of a sudden it gets a little burst of more power then stops. After seeing all of these posts, I am a bit worried since I have five kids that I haul around in this thing. :sick: It just hit 125K miles.
  • After having my van in the shop for a final look over before my extended warranty expired they diagnosed and determined that the spark plugs needed replaced. Between that and recalibrating the timing my issue was fixed.
  • 2004 Mercury Monterey . I replaced the PCM, according to the technical service bulletin there was an issue with condensation and poor drainage. I got one frm a junk yard for $40 and had it reprogrammed at the dealer. The one I took out clearly had been wet. I have also had to replace the ignition coil pack because it was faulty and had a hair line crack on the bottom side. Shook and jerked. Also replaced the Cam Shaft Sensor. The PCM short blew out my tail lights and radio began to freeze. Now I have replaced 3 pulleys on the thing because it chirps and whines. Now I believe the alternator pulley is bad. This is such a frustrating van. But on a lighter note I can take the cowl off and put it back on like I work for a Nascar pit crew.
  • Forgot to mention that I rigged a piece of weather stripping over the top of the PCM so it wouldnt get wet anymore and also silconed the windshield to the rubber to keep the thing from draining to the far right and left of the engine.

    Forgot to mention if you ever have to replace the balljoints on this dinger. They have to be done with the control arms as it is one piece. It required a motor mount to be removed on one side by the guys who did it.

    I really am disappointed in this purchase. This is my 5th ford and everyone has had some "thing" to contend with engine wise. I feel like a detective on this van tho.
  • Can you please tell me what the PCM is and where located so can have my husband check that? I also have a 2004 mercury monterey van...has 130,000 miles on it. I started experiencing same problems some time back. Thought needed a tune up job since had owned for 4 years with no problems whatsover. Right after the tune-up, the transmission went out with absolutely no warning whatsover-was well out of warranty so of course had to pay out of pocket for that. Right after getting out of shop for that had to replace one sensor which cant remember the name of but think was er valve and then the cam shaft positioner. The transmission went out AGAIN after maybe 4000 miles...if that many....thank God that was completely covered under warranty. Since then that cam shaft positioner was replaced again and the mechanic suggested taking to a dealership which is going to cost 80 bucks just to have them do a diagnostic. Needless to say, I am writing Ford but Im sure they wont do anything but this has been ridiculous to say the least. Appreciate any advice you can give. Thanks
  • dlshnndlshnn Posts: 2
    There has now been a recall of 2004-2005 Ford Freestar/ Mercury Monterey Torqu converter output shaft. It is NHTSA Campaign ID number : 12V006000.

    Here is the link earch&summary=true&refurl=email
  • danyaldanyal Posts: 1
    I have a 2004 Mercury Monterey minivan. It came with the built in dvd player, which my kids loved, well the radio went bad so we took it out. I was just curious do I have to replace it with a factory radio because of the built in dvd player or does it matter what i replace it with?
    Also, my automatic sliding doors will not open and shut automatically anymore : ( have to do it by hand and really have to shove on them, due you know what to do about them? It appears to have a lot of rust at the bottom, possibly a leak? Thank you in advance! : )
  • chage1chage1 Posts: 2
    edited August 2012
    Hi, Anyone else able to trace the water in the trans fluid issue? We have had many of the issues discussed here and our 2004 Mercury Monterey van only has 56,000 miles on it. (Replaced ignition coil, spark plugs, transaxle and torque converter-I guess because of the recall issue). We have also had issues with the sliding doors not staying shut (esp. driver's side) and my heated seat (driver's side) hasn't worked in over a year. Three different mechanics have not been able to figure out why there is water in the trans fluid. I pulled the 2 TSB's that deal with this issue (cowl panel grille and restricted transaxle vent tube) and they said there is no way the water can have gotten in that way. They all have asked me if I drove it into water (of course not and twice in the same year?!). The mechanic put in a separate trans cooler to make sure that there was no intrusion from the radiator, but less than a year later, same problems! My engine light is on continuously and I'm back to the car feeling like it's going to die when I hit 35-40 mph or go uphill and losing my reverse gear. The mechanic has ordered a new gear train, but tells me I will get the same issues if we cannot solve the water issue. What gives???? At least now I can get a reimbursement for the money we laid out for the torque converter-at least I hope so!
Sign In or Register to comment.