Catalytic Converter for Ford Freestar (2004-2007) 3.9L/4.2L Rear

Direct-Fit Rear Catalytic Converter for 2004-2007 Ford Freestar (V364)

What it Does: The rear catalytic converter treats secondary exhaust gases on the 2004-2007 Ford Freestar to eliminate P0420/P0430 DTC codes and restore factory emissions compliance without restricting exhaust flow.

The Stock Ford Freestar Catalyst Deterioration and Thermal Fatigue

Factory rear catalytic converters on the Ford Freestar paired with high-displacement Ford Essex V6 engines suffer from progressive thermal fatigue and internal washcoat depletion. Prolonged exposure to unburned hydrocarbons and thermal cycling degrades the OEM ceramic core, leading to structural sintering, internal matrix crumbling, and elevated exhaust backpressure. This degradation directly impedes downstream exhaust scavenge, causes persistent downstream O2 sensor fault codes, and chokes mid-range torque under heavy vehicle loads.

The Engineering Solution

Constructed with a heavy-gauge, corrosion-resistant stainless steel outer casing, this direct-fit rear catalytic converter restores structural integrity and proper flow dynamics. The internal assembly utilizes an engineered ceramic honeycomb substrate coated with a high-load precious-metal washcoat, ensuring optimal chemical reduction of NOx, CO, and HC emissions. Precision-stamped factory flanges and pre-positioned, welded sensor bungs guarantee exact alignment with the OEM exhaust routing, ensuring leak-free sealing without the need for custom pipe cutting or welding.

What's Included

• 1x Rear direct-fit catalytic converter assembly

Technical Specifications

Compatibility

• 2004 Ford Freestar 3.9L / 4.2L V6 (Rear)
• 2005 Ford Freestar 3.9L / 4.2L V6 (Rear)
• 2006 Ford Freestar 3.9L / 4.2L V6 (Rear)
• 2007 Ford Freestar 3.9L / 4.2L V6 (Rear)

Frequently Asked Questions & Fitment Warnings

Does this fit the V364 Freestar?

Yes, this is a direct fit for the 2004-2007 Ford Freestar equipped with the 3.9L or 4.2L Essex V6 engine in the rear position. EPA 49-state compliant only; not legal for sale or use in California, New York, Maine, or other CARB-mandated emissions states.

Does this replacement require cutting or welding?

No, this assembly matches factory flange dimensions and uses existing hanger positions for standard bolt-on installation.

The Ford Durability Standard

Engineered to handle sustained thermal cycles and continuous duty hauling, this exhaust replacement delivers OEM-level clearance, vibration resistance, and long-term emission compliance.