2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Ranger has 11 documented known issues, with 5 rated critical. The most serious are Leaf Spring Shackle and Hanger Corrosion Leading to Rear Suspension Failure ($400-$1,800 repair), Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk ($0-$400 repair), Takata Passenger Airbag Inflator Rupture Risk ($0-$0 repair), Timing Chain Guide and Cassette Failure on 4.0L SOHC V6 ($1,800-$4,000 repair) and Fuel Filler Neck and Strap Corrosion Causing Fuel Leaks or Tank Movement ($250-$900 repair). Across all issues with published estimates, repair costs range from $20 to $4,000. DIY maintenance guides at au7o.io.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Ford Motor Company (Ford) is recalling certain 2007-2011 Ranger, 2006-2012 Fusion, Lincoln Zephyr, Lincoln MKZ, 2006-2011 Mercury Milan, 2007-2010 Ford Edge, and Lincoln MKX vehicles. The driver's side air bag inflator may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
Ford Motor Company (Ford) is recalling certain air bag inflator and/or module replacement service parts that may have been used as part of a collision repair. The parts include certain driver-side air bag inflators and/or modules, designed to fit 2005-2014 Ford Mustang and Mustang GT500. It also includes certain passenger-side air bag inflators and/or modules designed to fit 2005-2014 Ford Mustang, 2010-2012 Lincoln MKZ, 2010-2012 Ford Fusion, 2010-2011 Mercury Milan, 2007-2011 Ford Ranger, and 2007-2010 Lincoln MKX vehicles. Please see Ford's recall report for the specific part numbers. These parts may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
AIR BAGS:FRONTAL
Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
Ford Motor Company (Ford) is recalling certain 2012 Ford Fusion and Mustang and Lincoln Zephyr and MKZ vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain 2009 Ford Ranger, Edge, Fusion and Mustang, Lincoln MKX, MKZ and Zephyr and Mercury Milan vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia and West Virginia, or "Zone B." Additionally, unless included in "Zone A" or "Zone B" above, Ford is recalling certain 2007-2008 Ford Ranger, Edge and Lincoln MKX, 2006-2008 Ford Fusion, Mercury Milan, Lincoln Zephyr and MKZ, 2005-2008 Ford Mustang and 2005-2006 Ford GT vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin and Wyoming. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
Ford Motor Company (Ford) is recalling certain model year 2007-2011 Ford Ranger vehicles, 2006-2011 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2007-2010 Ford Edge, Lincoln MKX vehicles, 2005-2006 Ford GT vehicles, and 2005-2011 Ford Mustang vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Ford is recalling certain model year 2007-2008 Ford Ranger, Edge and Lincoln MKX vehicles, 2006-2008 Ford Fusion, Mercury Milan and Lincoln Zephyr/MKZ vehicles, 2005-2006 Ford GT vehicles and 2005-2008 Ford Mustang vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Any vehicle not included in "Zone A", or "Zone B" is not included in the safety recall. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
+ 6 more recalls. Check all on NHTSA.gov
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Ranger has 11 documented issues. The most frequently reported are: Leaf Spring Shackle and Hanger Corrosion Leading to Rear Suspension Failure, Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk, Takata Passenger Airbag Inflator Rupture Risk. Of these, 5 are rated critical and should be addressed promptly.
The 2004 Ford Ranger has 11 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: Leaf Spring Shackle and Hanger Corrosion Leading to Rear Suspension Failure and Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk and Takata Passenger Airbag Inflator Rupture Risk and Timing Chain Guide and Cassette Failure on 4.0L SOHC V6 and Fuel Filler Neck and Strap Corrosion Causing Fuel Leaks or Tank Movement. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Ranger issues range from $0 to $4,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Leaf Spring Shackle and Hanger Corrosion Leading to Rear Suspension Failure, typically costs $400-$1,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
In rust-belt use, Rangers commonly suffer severe corrosion of the rear leaf spring shackles and hangers. Owners report the shackle tearing through rusted metal, causing the rear of the truck to sag suddenly or shift sideways. This is a real safety concern because the suspension c… Repairs typically run $400-$1,800. Severity: high.
A well-documented issue on early-2000s Rangers involves the speed control deactivation switch mounted on the brake master cylinder. Brake fluid can leak through the switch, overheat the electrical contacts, and in some cases cause smoke or an underhood fire even when the truck is… Repairs typically run $0-$400. Severity: high.
Many 2004-2011 Rangers were included in the Takata airbag campaign for passenger frontal inflators that can degrade over time, especially in hot and humid climates. In a deployment, the inflator can rupture and send metal fragments into the cabin, creating a severe injury or fata… Repairs typically run $0-$0. Severity: high.
The 4.0L SOHC V6 is widely known for timing chain guide and cassette wear, especially the rear cassette that is difficult to access. Owners report startup rattle, chain noise at idle, and eventually severe timing errors or engine damage if the plastic guides break apart. Because… Repairs typically run $1,800-$4,000. Severity: high.
Older Rangers in corrosion-prone regions frequently develop rusted fuel filler necks and weakened fuel tank straps. Owners report fuel smells, visible leaks while filling, EVAP faults, or in severe cases a sagging tank due to strap corrosion. This is both a drivability and fire-r… Repairs typically run $250-$900. Severity: high.
The 4.0L V6 uses a waste-spark coil pack with only three coils firing six plugs in paired cylinders, and it has a high failure rate — especially the end of the pack that serves the paired 3 & 4 cylinders (they share a secondary winding). A failing coil makes the misfire jump betw… Repairs typically run $100-$400. Severity: medium.
A recurring owner-reported problem on 2000s Rangers is intermittent failure of the instrument cluster, often traced to cracked solder joints or connector issues on the cluster circuit board. Gauges may drop to zero, warning lamps may flicker, and the odometer or backlighting can… Repairs typically run $150-$600. Severity: medium.
The 2.3L Duratec-equipped Ranger is known for coolant leaks from the thermostat housing assembly and related plastic cooling components. Owners report seepage or sudden cracking near the housing, leading to coolant smell, low coolant level, and occasional overheating if ignored. Repairs typically run $180-$650. Severity: medium.
A well-documented issue on late OHV/4.0L Ranger engines is wear of the camshaft synchronizer assembly, which drives the oil pump and provides the cam position signal. Owners commonly report a squeaking or chirping noise from the rear of the engine that is often mistaken for a bel… Repairs typically run $250-$900. Severity: medium.
Rangers from this era commonly develop sticky or failed door-ajar switches integrated into the latch assemblies. The truck may think a door is still open, leaving the dome light on, sounding the warning chime, or preventing normal locking behavior. This is a very common owner com… Repairs typically run $20-$300. Severity: low.
Many owners of 2000-2011 Rangers report intermittent high idle, unstable idle, or stalling when coming to a stop, often traced to a failing throttle position sensor, dirty or failing idle air control valve, or both. The problem is especially common on older cable-throttle trucks… Repairs typically run $100-$450. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
