2004 FORD RANGER Suspension Problems

FRONT SUBFRAME CROSSMEMBER THAT HOLDS SUSPENSION COMPONENTS HAS BROKEN DUE TO RUST.

Mileage: 110,000

THEFRONT SUBFRAME THAT HOLDS ALL THE SUSPENSION COMPONENTS HAS BROKEN DUE TO RUST.

Mileage: 110,000

THE FRONT SUBFRAME WHERE THE LOWER CONTROL ATTACHES HAS SEPARATED OR BROKEN DUE TO RUST. I WAS HEADED HOME FROM WORK, UNDER NORMAL DRIVING CONDITIONS, WITH NO EXTRA LOAD ON VEHICLE. I HIT A BUMP GOING THRU PARKING LOT N HEARD A POP. I HAD STOPPED AT GAS STATION N SEEN THAT DRIVER SIDE WHEEL N TIRE WERE NOT STRAIGHT UP N DOWN, IT WAS AT A DEGREE OR ANGLE. GOT UNDERNEATH N SEEN THAT SUBFRAME WAS RUSTED ALL THE WAY THRU WHERE LOWER CONTROL ARM WAS ATTACHED

Mileage: 110,000

INCREDIBLE AMOUNTS OF PREMATURE RUST ON FRAME AND SUSPENSION PARTS, SHACKLE BRACKETS RUSTED AWAY COMPLETELY AND HAD TO BE REPLACED. FRAME IS RUSTING AT AN UNPRECEDENTED PACE!?

Mileage: 83,000

FRAME RUSTED OUT ON PASSENGER SIDE BEHIND FRONT LEAF SPRINF MOUNT. ALSO THE CROSS MEMBER HOLDING FUEL TANK WHERE IT CONNECTS TO THE FRAME IS RUSTED OUT. ITS ONLY THE BACK HALF OF THE TRUCK RUSTING OUT THIS BAD. WHERE THE SPARE TIRE GOES IS ALSO COMPLETLY RUSTED OUT AND FELL OFF. THIS HAPPENED WHILE DRIVING ON SMOOTHLY PAVED ROADS TO AND FROM WORK

Mileage: 246,000

WHILE DRIVING, THE SPARE TIRE STARTED TO FALL OFF DUE TO RUSTING AWAY OF THE MOUNTING APPARATUS. LUCKILY I NOTICED IT WHEN I STOPPED FOR GAS (IT WAS HANGING BY ONLY A BIT OF STILL ATTACHED RUSTED METAL BELOW THE TRUCK) SO I CUT THE CABLE WITH SOME BOLT CUTTERS TO REMOVE THE SPARE AND PREVENT AN ACCIDENT WHILE DRIVING. DRIVER'S SIDE CAB MOUNT SEPARATED DUE TO EXCESSIVE RUST. DRIVER'S SIDE FLOOR BOARD FELL OUT DUE TO EXCESSIVE RUST - MY FOOT WENT THROUGH THE FLOOR. FRAME CRACKED NEAR REAR SHACKLE DUE TO EXCESSIVE RUST. FRAME CRACKED NEAR DRIVER'S SIDE REAR SHOCK MOUNT DUE TO EXCESSIVE RUST - EXCESSIVE PLAY AND NOISES CAUSED BE TO DISCOVER THIS. BED RUSTED COMPLETELY OUT - ABOVE WHEEL WELLS ON BOTH SIDES, CENTER OF BED, FRONT CORNERS. IT CAME OFF THE TRUCK IN SEVERAL PIECES AFTER I PUT MY FOOT RIGHT THROUGH THE CENTER. THE FRAME RUST ISSUES AND SPARE TIRE FALLING OFF COULD BE SERIOUS SAFETY PROBLEMS. I HAVE DRIVEN A NUMBER OF VEHICLES FOR MANY YEARS AND NEVER EXPERIENCED RUST ISSUES LIKE ON THIS TRUCK. WAY BEYOND WHAT IS REASONABLE AND EXPECTED.

Mileage: 180,000

REAR END OF FRAME COMPLETELY RUSTED OUT. LEAF SPRINGS BROKEN. SPRING SHACKLE BROKE OFF. BROUGHT THE TRUCK IN FOR SERVICE UNAWARE THERE WAS SO MUCH IRREPARABLE DAMAGE. DAMAGES OCCURRED WHILE DRIVING ON A CITY STREET. PIECES OF THE BODY WERE MISSING. EXACT DATE DAMAGES OCCURRED IS UNKNOWN.

FRAME RAIL NOT FORMED CORRECTLY DEFECTIVE.

Mileage: 170,000

THE PASSENGER SIDE FRAME RAIL RUSTED OUT.

Mileage: 146,900

AS I WAS DRIVING, THE BUMPER AND SPARE TIRE CAME OFF ALMOST CAUSING AN ACCIDENT.

Mileage: 72,000

THE REAR BUMPER FRAME HAS RUSTED OUT AND DETACHED FROM VEHICLE. LOADING BRUSH INTO TRUCK BED, STEPPED ON BUMPER, AND IT COLLAPSED. CHECKING THE REAR FRAME, SPRINGS, AND SUSPENSION SHOWS EXTENDED RUST, MAKING THE VEHICLE UNSAFE TO DRIVE.

Mileage: 91,500

THE REAR SPRING SHACKLE, BRACKET RUSTING AND FALLING OFF. THE GAS TANK BRACKETS RUSTED AND CAUSIING TANK TOO FALL OFF THE REAR FRAME ROTTED MAKING TRUCK UNSAFE FOR DRIVING ON THE ROAD THE FRONT FRAME OF TRUCK IS OK NO PROBLEM.IT IS JUST THE REAR FRAME RUSTED THRU.THE TRUCK WAS MAKEING A THUMPING NOISE AND WHEN I STOPED I HAD NOTICED THAT THE SPRINGS HAD BROKE THRU BED OF TRUCK PROMPTING ME TOO INSPECT FURTHER WHY THIS HAPPENED AND THAT IS WHEN I FOUND ALL THE OTHER ISSUES WITH THE FRAME.AND THE TANK.

Mileage: 78,511

EXCESSIVE RUST ON FRAME, SPINDLES, RACK AND PINION, DIFFERENTIAL AND WHEEL RIMS. VEHICLE HAS 48K ON ODOMETER. CAUSE:(UNKNOWN)

THE FRAME, UNDERBODY, SHOCKS, AXELS HAVE RUSTED. THE FRAME HAS ALMOST COMPLETELY RUSTED THROUGH. THE UPPER BODY HAS BEEN WELL MAINTAINED AND IS IN GREAT CONDITION.THIS VEHICLE ONLY HAS 84,000 MILES ON IT.

THE FRAME AND ALL ASSOCIATED COMPONENTS ROTTED AWAY. THIS LEFT THE SPARE TIRE DANGLING DANGEROUSLY UNSUPPORTED. THIS ALSO LEFT THE FUEL TANK UNSUPPORTED AND AT RISK OF FALLING AT ANY MOMENT. ALL DRIVE TRAIN COMPONENTS AND SUSPENSION ARE NO LONGER STABLE AND THE VEHICLE IS NO LONGER SAFE TO OPERATE. THE VEHICLE HAS ONLY 52,000 MILES.

SPRING SHACKLE FELL OFF, FRAME IS RUSTED, READY TO BREAK, CROSS MEMBER IS RUSTED OFF.

Mileage: 140,000

THE RIGHT REAR FRAME IS BADLY ROTTED TO THE POINT WHERE THE LEAF SPRING BROKE OFF THE FRAME. THAT ALLOWED THE BODY TO COME IN CONTACT WITH THE GAS TANK AND SHORTED OUT ONE OF THE TRANSMISSION WIRES. THE FRONT BUMPER IS RUSTED OUT ON THE PASSENGER SIDE CORNER. THE RUSTED FRAME IS THE BIG ISSUE.

Mileage: 145,000

TRANNY DROPPED DOWN CAUSING VIBRATION AND VEHICLE PULLED OFF ROAD AND TOWED. FOUND 2 CROSS SUPPORTS ROTTED AND SEPARATED ALSO.BODY OF TRUCK IS LIKE NEW. FRAME UNSAFE. TOYOTA RECALLED FOR THIS SAME REASON. FORD NEEDS TO BE HELD RESPONSIBLE ALSO. *TR

Mileage: 35,800

I OWN A 2004 FORD RANGER. THE FRAME IS TWO PARTS FRONT AND BACK HELD TOGETHER BY RIVETS. THE FRONT HALF OF THE FRAME LOOKS IN GOOD SHAPE, NORMAL WEAR AND TARE FOR A 2004 TRUCK BUT THE BACK SECTION OF THE FRAME INCLUDING SHOCK MOUNTS AND GAS TANK MOUNTS ARE A RUSTY ROTTING MESS. ITS LIKE PERFECT LINE. IF THE HOLE FRAME WAS LIKE THIS I WOULD SAY OK ITS A 2004 TRUCK BUT ITS NOT. SEEMS TO ME THIS IS A MANUFACTURER FLAW. *TR

TL* THE CONTACT OWNS A 2004 FORD RANGER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE REAR SHACKLES FAILED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS ADVISED THAT THERE WAS CORROSION AROUND THE CONTROL ARM WHERE IT WAS MOUNTED TO THE FRAME. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 61,000. UPDATED 06/18/14*LJ UPDATED 06/24/2014 *JS THE CONSUMER STATED THE REPAIR TECHNICIAN ADVISED THE STEEL RIM WAS LEAKING AT THE WELD SEAM WHERE THE TWO HALVES JOINED. THE SPARE TIRE RIM AND HOLDING DEVICE WERE RUSTED AND RENDERED THE TIRE COULD UNABLE TO BE REMOVED. THE VEHICLE WAS REPAIRED. UPDATED 06/24/2014 *JS

Mileage: 61,000

FRAME RUSTING OUT FROM UNDER TRUCK, NOISE WHEN I TURN TO STEER, AND SPARE TIRE FELL OFF. *TR

Mileage: 62,450

AT 45,000 MILES MY 2004 FORD RANGER 4X4 HAD A FAILURE OF THE FRONT WHEEL BEARINGS HUB CAUSING TIRE TO LOCK UP. NEEDED TO BE REPLACED. WAS TOLD BY THE REPAIR SHOP THERE WAS VERY LITTLE GREASE IN THE UNIT. *TR

Mileage: 45,000

WHILE DRIVING MY 2004 FORD RANGER, ONLY HAD 60,000 KM'S ON IT, DOWN THE HIGHWAY AT ABOUT 80 KMPH, THE LEFT SIDE OF THE REAR AXLE BROKE, AS I WAS GOING OVER A BRIDGE CAUSING LOSS OF CONTROL AND STRIKING A BRIDGE, TEARING UP 20 FEET OF GUARD RAIL AND RAILING 5 TIMES. THE AIR BAGS ALSO DID NOT DEPLOY AS THEY SHOULD HAVE AS FRONT BUMPER HIT BRIDGE RAIL DIRECTLY. WAS CLEANED UP BY POLICE AND TOW COMPANY. INSURANCE COMPANY HAD THE VEHICLE AND BELIEVE THEY MAY HAVE SCRAPED IT AS THEY DID NOT WANT IT ON THE ROAD AGAIN. *TR

Mileage: 60,000

COMPONENT: SUSPENSION:FRONT:WHEEL BEARING DETAILS: ON APRIL 26, 2008, A MINOR RHYTHMIC SQUEAKING SOUND WAS NOTICED FROM BENEATH VEHICLE WHILE DRIVING. ON MAY 3, 2008, UPON RAISING VEHICLE ON LIFT, MECHANIC NOTICED THAT THE ENTIRE RIGHT WHEEL ASSEMBLY INCLUDING BRAKE ROTOR, ABS COMPONENT AND HUB DROPPED FROM VEHICLE. AN ENTIRE WHEEL ASSEMBLY WAS NEEDED (+$500). AS AN EMT WHO RESPONDS TO VEHICULAR ACCIDENTS IN THIS RURAL STATE IN ALL KINDS OF WEATHER I WAS FLOORED TO THINK HOW CLOSE I WAS TO DRIVING THE VEHICLE AS THE WHEEL ASSEMBLY SEPARATED FROM THE RANGER. BASED UPON OTHER REPORTS (ODI CASE NUMBER: 10155010) I CONSIDER MYSELF FORTUNATE, THANK GOD. *TR

Mileage: 91,000

ON MARCH 06,06. EXACTLY 2 MONTHS AFTER TAKING DELIVERY OF A "QUALITY CHECKED PREOWNED " 2004 FORD RANGER PICKUP FROM A LOCAL DEALERSHIP WHILE DRIVING TO WORK AT 4:30 AM S/B ON THE I 15 SUDDENLY, WITHOUT WARNING THE VEHICLE VEERED HARD LEFT SLAMMED INTO THE CENTER GAURDRAIL THEN FLIPPED AND ROLLED CAUSING VEHICLE TO BE A CLASSIFIED AS A TOTAL LOSS BY INSURANCE CO. AFTER INSPECTION OF VEHICLE I WAS DRAWN TO THE FACT THAT THE FRONT LEFT WHEEL ASSEMBLY INCLUDING BRAKE ROTOR AND HUB WERE DETACHED FROM VEHICLE AND AFTER FURTHER INSPECTION IT APPEARS THAT THE WHEEL BEARING RETAINING ASSEMBLY IS AT FAULT. THE SPINDLE IS FLAT ON BOTH TOP AND BOTTOM OF THE THREADED TIP WHERE THE WHERE THE AXLE NUT THREADS SHOULD MESH AND HOLD, BUT THE THREADS OF THE NUT ARE DESIGNED IN SUCH A MANNER AS TO NOT BE CONTINUOUS,BUT INSTEAD THEY ARE SEPARATED TO WHERE 2/4 S OF THE INSIDE AREA IS THREADED AND THE OTHER 2/4 S HAS NO THREADS AND ARE STAGGERED IN SUCH A WAY AS TO ALLOW THE AXLE NUT IF ALLOWED TO SPIN AT ALL EVEN JUST 1/8 OF A TURN TO POP OFF WITH LITTLE RESISTANCE EXCEPT FOR THE SMALL LOOKING COTTER PIN WHICH CAME OUT IN PIECES MAYBE BECAUSE THE PRESSED METAL CASTLE NUT WANNA BE WHICH IS OF A LOOSE FITTING STYLE COULD EASILY HAVE WORN THE COTTER PIN WITH ITS RATHER SHARP EDGES SEEMINGLY FROM JUST NORMAL USE AND EVEN MORE SO IF THE WHEEL WAS NOT ADJUST PERFECTLY OR IF THE WHEEL SEAL WAS NOT SEATED PERFECTLY WHICH AFTER SOME TIME WOULD CAUSE A MORE PRONOUNCED LOOSENESS IN THE WHOLE ASSEMBLY THUS CAUSING THE AFOREMENTIONED DANGEROUS RESULTS. I WAS SHOCKED WHEN I SAW THE SYSTEM USED AND I CANNOT FOR THE LIFE OF ME WHICH I AM LUCKY TO STILL HAVE UNDERSTAND HOW THAT DESIGN COULD BE CONSIDERED SAFE ABOVE OTHER DESIGNS THAT ARE OF SOLID MATERIALS WITH CONSTANT THREADS THAT WOULD HAVE TO SPIN COMPLETELY OFF MANY COMPLETE TURNS RATER TAN JUS 1/8 TO 1/4 OF ONE TURN. PLEASE WOULD YOU LOOK INTO THIS BEFORE OTHER TRUCKS MAKE UNANNOUNCED TURNS FOR THE WORSE. THANK YOU.

Mileage: 35,400

FRONT SUSPENSION CAUSES SHIMS NEEDED IN FRONT END ALIGNMENT TO WEAR PREMATURELY AND CAUSE FRONT TIRES TO WEAR INCORRECTLY ON INSIDE OF FRONT TIRES. NEEDED TO GET FRONT END ALIGNMENT. FORD KNOWS ABOUT THIS AND DOES WARRANTY THESE PART FOR 12,000 MILES OR 12 MONTHS. SPOKE WITH FORD TECH AND AGREED WITH ME THAT THIS PROBLEM IS NOT NOTICEABLE UNTIL WELL AFTER THAT TIME FRAME. *NM

Mileage: 30,000

DT*: THE CONTACT STATED WHILE THE VEHICLE WAS TAKEN TO THE DEALER FOR REGULAR MAINTENANCE, THE TIRES WERE WORN. UPON INSPECTION, THE TECHNICIAN DISCOVERED THE REAR SUSPENSION SETTLED AFTER A PERIOD OF TIME AND RESULTED IN EXCESSIVE WEAR IN THE MIDDLE OF THE TIRES. THE VEHICLE IS CURRENTLY UNDERGOING ADDITIONAL TESTING BEFORE REPAIRS ARE MADE.

Mileage: 34,000

MY 2004 FORD RANGER PICKUP HAS 45,265 MILES ON THE ODOMETER. I BROUGHT THE VEHICLE TO THE LOCAL FORD DEALERSHIP TO GET BRAKE WORK DONE PLUS ANOTHER ISSUE AS OUTLINED IN NHTSA COMPLAINT/CONFIRMATION#10151518. I WAS TRYING TO GET MY VEHICLE AN INSPECTION STICKER FOR THE STATE OF MASSACHUSETTS AS WELL. I WAS TOLD THAT I NEED NEW LOWER BALL JOINTS PN#F87Z-3050-BA IN ORDER TO GET MY STICKER. MY VEHICLE IS A 2004, WITH 45.264 MILES OF HIGHWAY AND SECONDARY ROAD USAGE ONLY! NO OFF ROAD OR SEVERE USAGE AT ALL! BALL JOINT REPLACEMENT AND REQUIRED FRONT-END ALIGNMENT COST ME OVER $430.00! I HAVE THE BAD BALL JOINTS IN MY POSSESSION. VEHICLE IS DRIVEN BY ME DAILY, TO AND FROM WORK ONLY!*JB

Mileage: 45,264

WE NOTICED EXTREME TIRE WEAR ON THE RANGERS FRONT TIRES, WHICH AT THE TIME HAD 7840 MILES ON IT. I IMMEDIATELY TOOK THE VEHICLE TO BAY HARBOR FORD. THE SERVICE PERSON EXPLAINED THAT THE TIRES WERE ONLY WARRANTEED FOR 12 MONTHS OR 12,000 MILES. *AK ON APRIL 27TH , I ARRIVED EARLY AND SPOKE TO THE SERVICE MANAGER, MR. JIM BASILOTTO. HE LOOKED AT THE VEHICLE AND AGREED THERE WAS AN ALIGNMENT PROBLEM. I EXPLAINED THAT THE VEHICLE IS GARAGE KEPT AND IT IS ONLY DRIVEN BACK AND FORTH TO WORK ON THE LOCAL ROADS. THE VEHICLE HAS NEVER BEEN OFF- ROAD OR EVEN ON BAD ROADS AND NEVER TRAVELED FARTHER THAN PORT CHARLOTTE, FL. SHE OR I CAN NOT EVER REMEMBER HITTING A POTHOLE THAT WOULD COME CLOSE TO CAUSING A PROBLEM. THE SERVICE PEOPLE PUT THE CAR ON THE LIFT AND CHECKED THE TIE RODS BY TRYING TO WIGGLE THEM WHILE THE VEHICLE HAD ITS FULL WEIGHT ON THE TIRES. ( I PERSONALLY CHECK FRONT END PARTS BY RAISING THE WHEELS OFF THE GROUND AND CHECK FOR PLAY IN THE BALL JOINTS ALSO) THE TIRE PRESSURE IN ALL 4 TIRES WAS LOW (LOWER 20 PSI) AND THEY ADDED AIR. AGAIN THE TIRE PRESSURE IS AS IT WAS WHEN IT LEFT THE SHOWROOM. IT IS OUR CONCLUSION THAT THE ALIGNMENT PROBLEM HAD TO EXIST WHEN WE LEFT THE DEALERSHIP WITH THE VEHICLE AND SHOULD BE COVERED UNDER THE WARRANTY. IN COMPARISON, MY 2001 EXPLORER HAS 53,000 MILES ON IT AND THE TIRES ARE IN GREAT SHAPE. IT HAS BEEN OFF ROAD ON MANY OCCASIONS, THROUGH THE WORST BONE JARRING POTHOLES ON THE CROSS BRONX EXPRESSWAY AND NEVER HAD ANY ALIGNMENT PROBLEMS. I NOW HAVE TO PAY TO GET A WHEEL ALIGNMENT AND A NEW SET OF TIRES FOR THE RANGER AND IT ONLY HAS 7845 MILES ON IT. I FEEL THAT THE DEALERSHIP SHOULD HAVE COVERED THE TIRES AND ALIGNMENT UNDER THE 3 YEAR , 36,000 MILE BUMPER TO BUMPER WARRANTY.

Mileage: 7,840