2004 Ford Ranger Suspension Problems

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

NHTSA ID

11350038

Incident

Jul 9, 2020

Mileage

110,000 mi

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

NHTSA ID

11350035

Incident

Jul 9, 2020

Mileage

110,000 mi

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

NHTSA ID

11349154

Incident

Aug 2, 2020

Mileage

110,000 mi

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!?

NHTSA ID

11340818

Incident

Jul 16, 2002

Mileage

83,000 mi

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

NHTSA ID

11271490

Incident

Oct 1, 2019

Mileage

246,000 mi

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.

NHTSA ID

11244193

Incident

Oct 12, 2018

Mileage

180,000 mi

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.

NHTSA ID

11243722

Incident

Aug 2, 2019

FRAME RAIL NOT FORMED CORRECTLY DEFECTIVE.

NHTSA ID

11203487

Incident

Apr 3, 2019

Mileage

170,000 mi

THE PASSENGER SIDE FRAME RAIL RUSTED OUT.

NHTSA ID

11193472

Incident

Feb 19, 2018

Mileage

146,900 mi

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

NHTSA ID

11122864

Incident

Aug 27, 2018

Mileage

72,000 mi

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.

NHTSA ID

11119589

Incident

Aug 1, 2018

Mileage

91,500 mi

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.

NHTSA ID

11065527

Incident

Jan 20, 2018

Mileage

78,511 mi

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

NHTSA ID

11042054

Incident

May 15, 2016

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.

NHTSA ID

11030634

Incident

Jul 12, 2017

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.

NHTSA ID

10980509

Incident

Jun 1, 2016

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

NHTSA ID

10716959

Incident

Nov 8, 2014

Mileage

140,000 mi

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.

NHTSA ID

10715329

Incident

Aug 4, 2014

Mileage

145,000 mi

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

NHTSA ID

10694326

Incident

Mar 8, 2015

Mileage

35,800 mi

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

NHTSA ID

10587632

Incident

Mar 18, 2014

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

NHTSA ID

10585630

Incident

Jan 15, 2014

Mileage

61,000 mi

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

NHTSA ID

10583908

Incident

Apr 18, 2014

Mileage

62,450 mi

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

NHTSA ID

10373587

Incident

Dec 23, 2010

Mileage

45,000 mi

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

NHTSA ID

10269302

Incident

Dec 15, 2008

Mileage

60,000 mi

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

NHTSA ID

10227476

Incident

Apr 26, 2008

Mileage

91,000 mi

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.

NHTSA ID

10155010

Incident

Mar 6, 2006

Mileage

35,400 mi