Badge re-engineering: updated Freestar aims for its fair share of a resurgent minivan market

Automotive Industries, Nov, 2003 by John Peter

Freestar also has optional side-impact chest air bags and a roll-over safety canopy developed in conjunction with TRW. The dual-function side-curtain system is supplied by Autoliv. Accelerators mounted around the cabin deploy the side curtain upon impact or roll-over. If the vehicle continues to move, the side curtains will stay inflated for up to six seconds.

Freestar now features a failsafe cooling system that allows the vehicle to be driven safely when there is a significant loss of coolant. If the coolant-level sensor reads below a critical amount it alerts the engine computer module which switches the engine into an emergency limp-home mode, in which only half of the cylinders get fuel. The ECM fires one cylinder at a time, creating enough power to get to a safe place.

Freestar comes standard with a back up warning system and Freestar owners can opt for adjustable pedals and self-sealing tires.

Freestar's suspension was re-engineered to improve ride and handling. The MacPherson strut front suspension has liquid-filled rear lower control arm bushings. Sheer-style front sub frame mounts aid steering control and provide a comfortable ride.

The semi-independent twist beam rear suspension is further stiffened with a pan hard rod.

Shocks have been tuned for a smooth ride and superior body control, eliminating body roll when cornering.

The power assist rack and pinion steering system was retuned for Freestar. The system has new gearing and valving with a stiffer intermediate shaft, new power boost curve and improved alignment settings for a good on-center feel. Steering effort builds progressively off-center creating a feeling of stability when driving at higher speeds, yet making it easier to maneuver into tight parking spaces.

Freestar is equipped with four-wheel disc brakes and an optional AdvanceTrac stability system. Seven different sensors monitor steering wheal angle, throttle position, wheel speed and the vehicle's yaw rate, among other things every seven milliseconds.

If the system senses that the vehicle is deviating from the driver's intended path, brake pressure is applied to the appropriate wheel to help stabilize the car (outside front wheel for under steer, inside rear wheel for over steer). The system can also reduce engine power if necessary.

DuComb says that Ford considered an AWD option at the onset of the program. The idea was scrapped due to the extra cost of redesigning the platform to accept the system.

There would also have been extra costs relating to manufacturing assembly time and the cost of tooling and manufacturing extra parts. DuComb says that the program team felt that they could do everything with Advance Trac at a considerable cost savings.

The Freestar interior has been completely re-designed. The new IP is clean and functional and features a small storage compartment built into the top. That's just a miniscule piece of the overall storage system, a necessity in a minivan. There are storage pockets on all the door inners, and the cup holders (ten in all) on the front door will hold 20-ounce bottles. Limited models include a kangaroo pouch on the front of the passenger seat.