This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.
So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.
The right rear leaf spring shackel broke off from the frame due to rust. The spare tire carrier failed due to rust and caused the spare tire to drop. The steel shield under the gas tank dropped down due to rust.
I took my truck in for tire repair and service technician found severe rotting where leaf springs are supposed to be connected to the frame. There was a total disconnect at this location which explains the loud banging that I've been hearing. This is on the drivers side. He advised me that on the passenger side, it was the same situation but it wasn't disconnected yet. He advised me Ford Ranger have a problem with this. I went online and discovered a huge volume of complaints regarding this same issue. Some complaints said that they were driving when their truck bed gave way and collapsed while in the truck was in motion. This truck was handed down with low mileage and little reason for all that rust/rotting in the frame of the truck. I was advised that had I been carrying a medium or heavy load the bed could have given way, and that could have been in motion.
Picked up kids from bus stop (5 and 6 years age) with 2001 Ranger parked in gear on gravel driveway grade with emergency brake engaged. Loaded kids and myself, started vehicle and released emergency brake. Brake pedal went to floor, vehicle took off down hill. Pushed and pumped pedal hard to engage rear brake valve; no rear brakes. Engaged emergency brake (now at considerable speed on grade). Left rear wheel locked skidding vehicle to right side on gravel drive, corrected with steering avoiding roll over. Subsequent inspection revealed extensive premature corrosion to vehicle frame, suspension and brake components. Both front and rear brake lines compromised with catastrophic failure during emergency. My kids and I could have been killed or injured because Ford saved a few bucks using below standard imported steel. Ntsb; are you in some way being paid-off by Ford to ignore the thousands of safety complaints and incidents associated with extensive corrosion on these vehicles" do not even attempt to assign blame on salty eastern roads; many other vehicle driven under identical conditions do not fall apart so consistently and completely. Many undercarriage parts on my Ranger are not even recognizable due to near complete disintegration. My truck has an 'a' title and was rust proofed prior to delivery. I take good care of my vehicles and regularly wash undercarriage. How many people will be injured or killed before action is taken"
Failed component 2: frame ahead of leaf spring shackles on both sides. Left was completely fractured and right was 1/2 fractured. Right shock strut mount broken. Driving around town hit several bumps in road due to road construction. When I parked the truck I noticed the truck bed was leaning to the right. Further inspection revealed a cracked frame. Took it to the shop and they said it wasn't safe to drive. They removed the bed and noticed extreme rust and a 'paper thin' frame.. said it would be difficult to find good metal to weld to. I noticed that Ford had a recall on the 2004 Ranger frame.
Symptoms included engine stall during highway and uphill driving. Stopped at fuel station to fill tank; when tank approached full; sound of structural failure noted followed by large fuel spillage from tank area (saturated truck rt rear underbelly, ground, rear tire, my shoes and lower portion of pants). Subsequent inspection revealed gas tank strap detached from frame due to severe and widespread frame rot. Tank apparently hanging from remaining corrosion damaged strap and fuel filler neck (caused tank to tilt backwards; starving engine of fuel during uphill or dynamic driving). Fuel filler neck was also severely rotted and finally failed during fuel fill causing entire tank loaded with 16 gallons fuel to become detached at sharp angle. Following incident; vehicle professionally inspected revealing extensive frame and suspension component disintegration due to premature failure of Ford designed sub-standard materials. Large areas of material missing from both front frame members (rear of engine), large holes in frame areas forward of rear wheels (where fuel tank straps attack), severe and widespread frame and suspension component corrosion. Vehicle condemned by inspection personnel; now sits idle in driveway. Ranger purchased new (year end, 2001) with dealer rust-proof. Vehicle regularly maintained and kept free from road salt with regular underbelly wash. Vehicle only had 120,000 miles and looked very clean on exterior. I have owned many vehicles in my 35 year driving history; never have I experienced anything like this prior. Ford obviously used ultra-sub standard materials in Ranger critical suspension component designs; without regard for the safety of unsuspecting owners. This is criminal, it will only be a matter of time before people are injured or killed by these design defects.
- Georgetown, PA, USA
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Went to rear of truck and found bumper had broken free on the drivers side. Looked under the tuck and found that the entire frame in the rear is rotted and the leaf springs are in danger of coming completely off. The bumper is entirely free from the truck. The passenger side of the frame directly over the tire is cracked completely through. This is the worst frame I have ever seen and have lived through the 70's american car manufacturers mess.
I attached a yard trailer to the receiver hitch and as I pulled out of the yard the hitch pulled right off the back of the truck. I looked under the truck and saw about a foot of the rear frame rails were completely rusted away on both sides. Both rear leaf spring mounts were broken away and the springs were pushed up onto the bed of the truck. This truck has less than 60,000 miles on it and no apparent rust. If this had happened on the highway the trailer would have gone sailing down the highway possibly causing an accident. Both rear springs detached from the frame and if I had been on the highway, there is a good chance I would have lost control of the truck.
The contact owns a 2001 Ford Ranger. After examining the vehicle, the contact noticed that the entire frame and sub frame had cracked and rusted through. The vehicle was taken to a local mechanic on several occasions, where the leaf springs were replaced each time. The failure mileage was 110,000 and the current mileage was 140,000. The VIN was unavailable.
2001 Ford Ranger was taken into auto shop for routine maintenance. The mechanic inspected the vehicle and found the rear spring shackles and the frame rotted and about ready to fail completely. The springs were found to be pressing up on the bottom of the frame. Also noted bumper was about ready to fall off. All of this due to severe corrosion of the frame. No maintenance was performed on the vehicle and a recommendation from the mechanic to remove the vehicle from the road was advised.
During my annual inspection it was noted that the rear leaf spring bracket was rusted off and part of the frame had rusted away. Would not pass safety inspection....
The driver's side rear shackle welds broke for the leafspring support. It made a clunking noise, so I checked it & seen that it was broke. Were then I noticed the truck box being lifted on that side.
Rear of frame has rusted away. Rear bumper is ready to fall off. Left spring up against bed floor. This truck has the original exhaust on it no other problems ever I use Ford 5W20 syn. Blend oil, changed every 3,000 miles. Guess I wasted all that money"? I get 24 miles to the gal. Highway. Now I cant take it there. Still looks good setting in my driveway. I am 68 yrs.old, my only veh. No money for another vec. Now what???" thanks for letting me ramble.........[xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).
Rear wheel assembly (wheels, axle, leaf-springs) became detached from frame due to severe and premature frame and leaf-spring bracket corrosion (failure caused abrupt pull to center of highway at speed, fortunately no accident, since I am a pretty good driver). Subsequent inspection revealed extensive corrosion associated with vehicle frame and critical suspension components. Leaf spring brackets and various other suspension components noted to be manufactured from ultra-low carbon steel (known to turn to dust when exposed to weather). Vehicle is a 2001 with only 113,000 miles; truck is basically junk at this point with no chance of replacing the numerous components effected. I replaced the leaf-spring brackets; however I am fearful to drive the vehicle since it may kill me. Good job Ford instilling customer safety, satisfaction and quality engineering. Hope the few bucks you saved by using sub-standard materials on critical suspension components was worth it. I guarantee my family will never purchase another Ford product. -husband, father of two...
Frame was noted to have severe rust damage to rear portion of frame, however, the front portion ofthe frame does not show such damage. I have done research on this issue and it seems to be so common that there is an after market frame repair kit for this specific vehicle. The truck has no other issues. I believe that it sould not be much to ask to have defect repaired by the manufacturer to avoid safety issues.
Truck has 86,000 and looks like brand new condition, however, the frame is badly rusted, our auto mechanic has told me that the trucks life is coming to an end. Contacted Ford and they said there is an ongoing investigation and they can not comment at this time. I asked if they would help pay for a frame replacement which they declined.
A D V E R T I S E M E N T S
- Marstons Mills, MA, USA