maintenance FORD FREESTAR 2004 1.G Repair Manual

The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
tires and chains. If you need to use chains, it is recommended that steel
wheels (of the same size and specifications) be used as chains may chip
aluminum wheels.
Follow these guidelines when using snow tires and chains:
•Use only cable type SAE Class “S” chains. Conventional link or other
type chains may cause damage to your vehicle’s wheelhouse and/or
underbody.
•These cable type chains should only be applied to the front wheels.
•Install chains securely, verifying that the chains do not touch any
wiring, brake lines or fuel lines.
•Drive cautiously. If you hear the chains rub or bang against your
vehicle, stop and re-tighten the chains. If this does not work, remove
the chains to prevent damage to your vehicle.
•If possible, avoid fully loading your vehicle.
•Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
•The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
MOTORCRAFT PART NUMBERS
Component 3.9L OHV V6 engine 4.2L OHV V6 engine
Air filter element FA-1711 FA-1711
Battery BXT-59 BXT-59
BXT-65-750 BXT-65-750
Fuel filter FG-986B FG-986B
Oil filter FL-400S FL-400S
PCV valve EV-261 EV-261
Spark plugs* AWSF-42EE*** AWSF-42EE***
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
*** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, and 3 have a “EG” suffix. Cylinders No.
4, 5, and 6 have a “E” suffix. If a spark plug needs to be replaced, use
only spark plugs with the service part number suffix letter “EE” as
shown on the engine decal.
2004 Windstar(win)
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Maintenance and Specifications
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REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid
1
All Fill to MAX line
on reservoir
Engine oil
(includes filter
change)
3
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)3.9L engine 4.7L (5.0
quarts)
4.2L engine 4.7L (5.0
quarts)
Engine coolant
2Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)Without rear
heater14.0L (14.8
quarts)
With rear heater 15.0L (15.9
quarts)
Power steering
fluidMotorcraft
MERCONAT FAll Fill to line on
reservoir
Fuel tank N/A All 98.4L (26.0
gallons)
Automatic
transaxle fluidMotorcraft
MERCONV
AT FAll 13.0L (13.7
quarts)
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll Fill to line on
reservoir
1Use only brake fluids certified to meet Ford specifications. Refer to
Lubricant Specificationsin this chapter. DOT 3 fluid is recommended.
However, if DOT 3 is not available, DOT 4 fluid can be used.
2Add the coolant type originally equipped in your vehicle.
3Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C153–H and the API Certification mark.
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LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid
1
PM-1 ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantXL-6 ESR-M13P4-A
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow colored)VC-7–A WSS-M97B51-A1
Engine oil Motorcraft SAE
5W20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)
XO-5W20-QSP
(US)
CXO-5W20–LSP12
(Canada)WSS-M2C153-H
with API
Certification
Mark
Door latch, hood
latch, auxiliary
hood latch, door
and liftgate
hinges, striker
plates, seat
tracks, sliding
door both sides
(upper and
lower track) and
fuel filler door
hinge.Multi-Purpose
GreaseXG-4 or XL-5
ESB-M1C93-B
orESR-M1C159-A
Lock cylinders Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONAT FXT-2-QDX MERCON
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Item Ford part
nameFord part
numberFord
specification
Automatic
transaxle
(4F50N)Motorcraft
MERCONV
AT F
2
XT-5-QM MERCONV
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-3 ESE-M1C171-A
Constant
velocity jointsMotorcraft CV
Joint Grease
(High Temp.)XG-5 WSS-MIC258-A1
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
1Use only brake fluids certified to meet Ford specifications. DOT 3 fluid
is recommended. However, if DOT 3 is not available, DOT 4 fluid can be
used.
2Ensure the correct automatic transmission fluid is used MERCONand
MERCONV are not interchangeable. DO NOT MIX MERCONand
MERCONV. Refer to the scheduled maintenance guide to determine the
correct service interval.
ENGINE DATA
Engine 3.9 L OHV V6 engine 4.2L OHV V6 engine
Cubic inches 232 256
Required fuel 87 octane 87 octane
Firing order 1-4-2-5-3-6 1-4-2-5-3-6
Spark plug gap 1.3-1.4 mm
(0.052-0.056 inch)1.3-1.4 mm
(0.052-0.056 inch)
Ignition system EDIS EDIS
Compression ratio 9.36:1 9.27:1
2004 Windstar(win)
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VEHICLE DIMENSIONS
Vehicle dimensions Wagon mm (in) Van mm (in)
(1) Overall length 5105 (201.0) 5105 (201.0)
(2) Overall width 1945 (76.6) 1945 (76.6)
(3) Overall height 1741 (68.5)
11742 (68.6)2
(4) Wheelbase 3069 (120.8) 3069 (120.8)
(5) Track - Front 1644 (64.7) 1644 (64.7)
(5) Track - Rear 1595 (62.8) 1595 (62.8)
1Equipped with P225/60R16 tires.
2Equipped with P235/60R16 tires.
2004 Windstar(win)
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IDENTIFYING YOUR VEHICLE
Certification label
The National Highway Traffic Safety
Administration Regulations require
that a Certification label be affixed
to a vehicle and prescribe where the
Certification label may be located.
The Certification label is located on
the front door latch pillar on the
driver’s side.
1
4
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Vehicle identification number (VIN)
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel. (Please note that
in the graphic XXXX is
representative of your vehicle
identification number.)
1. World manufacturer identifier
2. Brake type and gross vehicle
weight rating (GVWR)
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block, transmission, frame and
transfer case (if equipped).
XXXXXXXXXXXXXXXXX
2004 Windstar(win)
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Transmission/Transaxle code designations
You can find a transmission/transaxle code on the vehicle certification
label which is located on the door pillar. The following table tells you
which transmission or transaxle each code represents.
Truck application:
Code Transmission Description
Manual transmission
M Manual 5–speed overdrive (Mazda R2)
C Manual 5–speed overdrive (Close ratio)
W Manual 5–speed overdrive (Dana ZF)
G Manual 6–speed ZF
Automatic transmission
U Automatic 4–speed overdrive (4R70W)
T Automatic 4–speed overdrive (4R44E)
E Automatic 4–speed overdrive (4R100)
J Automatic 5–speed overdrive (5R55E)
2004 Windstar(win)
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Code Transmission Description
Electric
H One speed electric
D Automatic 5–speed overdrive (5R44E)
R Automatic 5–speed overdrive (5R55S)
Passenger car application:
Code Transmission/Transaxle Description
Front wheel drive manual transaxle
R 5–speed overdrive (MTX75)
W 5–speed overdrive (M5)
Front wheel drive automatic transaxle
E 4–speed overdrive (4FE)
J 3–speed (Mazda)
L 4–speed overdrive (AX4S)
P 4–speed overdrive (4F20E)
X 4–speed overdrive (4F50N)
Y 4–speed overdrive (CD4E)
Rear wheel drive manual transaxle
5 5–speed (Mazda M5)
Rear wheel drive automatic transmission
U 4–speed overdrive (4R70W)
A 5–speed overdrive (5R55N)
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A
Accessory delay ..........................64
AdvanceTrac ..............................168
Air bag supplemental restraint
system ........................138, 144, 146
and child safety seats ............140
description ..............138, 144, 146
disposal ....................................149
driver air bag ..........141, 145, 147
indicator light .................140, 149
operation .................141, 145, 147
passenger air bag ...141, 145, 147
side air bag ..............................144
Air cleaner filter .......................263
Air filter, cabin ............................41
Antifreeze
(see Engine coolant) ................233
Anti-lock brake system
(see Brakes) ......................167–168
Anti-theft system ......................101
arming the system ..................101
disarming a triggered
system .....................................101
Audio system
(see Radio) ................18, 20, 23, 26
Automatic transaxle .................171
fluid, adding ............................248
fluid, checking ........................248
fluid, refill capacities ..............264
fluid, specification ..................266
Automatic transmission
driving an automatic
overdrive .................................172
Auxiliary power point .................62
Axle
lubricant specifications ..........265
B
Battery .......................................231acid, treating emergencies .....231
jumping a disabled battery ....203
maintenance-free ....................231
replacement, specifications ...263
servicing ..................................231
BeltMinder .................................132
Brakes ........................................167
anti-lock ...........................167–168
anti-lock brake system (ABS)
warning light ...........................167
fluid, checking and adding ....248
fluid, refill capacities ..............264
fluid, specifications .........265–266
lubricant specifications ..265–266
parking ....................................168
shift interlock ..........................171
Bulbs ............................................48
C
Capacities for refilling fluids ....264
Cargo net .....................................84
Cassette tape player..18, 20, 23, 26
Cell phone use ............................70
Certification Label ....................268
Child safety restraints ..............150
child safety belts ....................150
Child safety seats ......................152
in front seat ............................154
in rear seat ..............................154
tether anchorage hardware ...156
Cleaning your vehicle
engine compartment ..............220
instrument panel ....................222
interior .....................................222
interior trim ............................222
plastic parts ............................221
washing ....................................219
2004 Windstar(win)
Owners Guide (post-2002-fmt)
USA English(fus)
Index
Index
274