Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford Ranger owners, lightly cleaned up (personal details are redacted by NHTSA).
We are original owners of a 2002 Ford Ranger xlt now with 57,000 highway miles, always garaged/washed/maintained, little driving in winter (mostly in summer), always Ford maintained/serviced at same dealership, body/engine/transmission in great shape, will likely fail inspection this sping because frame and frame components are severely rusted out. - severe rust on the entire frame including both cross members (engine and transmission), arm bolt points and control arms. - frame also has severe rust down both sides to rear bumper, rear axle and differental, leaf springs and all mounts. - the passenger side stearing knuckle is delaminating. - all brake lines have failed while driving: first the rear brakes including all axle couplings and drum couplings; second the front brake lines failed at the disk brakes and rubber couplings. …
Excessive rust underneath. Leaf spring hangers failed at 11 years/120K miles. Spare tire winch separated from truck at 14 years/155K miles. . An exhaust mount has rusted away leaving the exhaust system marginally supported - uncertain of when this happened. Logging this complaint due to the gas tank strap failure. One gas tank strap separated from underneath the truck bed approximately one month ago - age 14.5 years, ~160K miles. With the spare tire, I noticed it hanging low (3 of 4 fasteners had pulled away from their mounts), and with little effort, was able to have it fall off. Had the remaining fastener failed on the highway, obviously bad things could have happened. With the gas tank strap, luckily it separated from underneath the bed rather than from the frame, and I could hear it rubbing against the drive shaft. …
Rear tire fell out onto road, rotted carrier , frame rotted at axle, cracked in half while driving on highway, rear end shifted, can know longer drive vehicle safely, had to buy new truck days later! Body in good shape, frame totally rotted! So many other complaints about same thing on google search. Toyota Toyota had same thing, we called all their trucks and replaced all truck f we called all their trucks and replaced all truck frames frames, still to this day Ford has not recognized a major problem with their frames!!! These vehicles are a major safety hazard on the road and a recall needs to happen !!
Rear leaf shackles replaced, rotted from frame, last aug 2014 to pass inspection. This winter 2014-2015, the spare tire carrier frame rotted and fell from the vehicle, including the spare tire. Now, upon inspection of the bed appearing crooked, the drivers side frame in front of the drivers side front leaf spring mount is totally rotted. This has caused the gas tank mounts to the frame to break. It has also caused the bed to twist and the entire rear end of this vehicle is now only supported by the passenger side frame.
I bought this truck from a dealership in jan 2010. Truck was in good shape, had frame check out before I bought it and looked very good. Truck had only 48000 miles on it. In jan of 2015 the truck bed sat a little crooked check frame and seen a crack on frame 3' long by front shackle. At that time truck only has 94000 miles on it. Took bed off and found more areas that would need adressing soon. I tried to keep truck under side clean during the winter, I guess the stuff the state uses on the road was to much for the truck.
Was pulling into friends driveway when I heard a cracking noise when I checked the left rear spring hanger pulled out of the rusted frame. I pulled off the bed of the truck and found several areas which were severely rusted including the spare tire carrier and the straps which hold up the gas tank. I am the original owner of the vehicle and have lived in pennsylvania the whole time.
Bracket for spare tire rotted, tire dropped off, no car in back of me, didn't know what happen at the time, that happened 6 month after I bought it, the other day the frame cracked in half. Car dealer ship sold truck to me roughly 15 month ago truck is totaled. Insurance adjuster said whole frame and under carriage is rotted? Help. Exterior of truck looks brand new? Help
I bought my Ranger new, it currently has 232,000 miles. Frame rust is so bad it is unsafe to drive. Rear spring shackle mounts rusted away, bed is resting on springs. Rust rains from underneath when hood is allowed to close. Brake line mounts are nearly gone, as is gas tank straps. I have never seen frame rot this bad, even in northern states where road salt is used.
Rear bumper and spare tire holder rotted off .. Rear shackles on both sides.. Gas tank straps and crossmember that holds it up... Now the frame has rotted in half right in middle of truck... Spare tire fell off while driving
Vehicle has a slight vibration at 65 MPH that increases in severity as speed increases. At 85 MPH it has a very pronounced vibration that must be considered dangerous. Vehicle was returned to dealer four times. The dealer essentially told customer that Ford would not warranty a vehicle over the legal speed limit. This was the final answer after several attempts were made to convince the customer of other causes, most of which were essentially ridiculous. (the customer was in the auto repair business for 17 years.) the customer took the technician for a test drive to demonstrate the severe vibration. The technician proposed the possibility of a defective rear drive line. The technician's supervisor then drove the vehicle himself then stated the vehicle definitely had a pronounced vibration, but Ford would not warranty the problem. …
Suspension complaints in other Ranger years
Frequently asked questions
How common are suspension problems on the 2002 Ford Ranger?
NHTSA has 36 complaints about the suspension of the 2002 Ford Ranger, 10% of the model year's 346 complaints. The component named most often is front (2 mentions).
Is there a recall for 2002 Ford Ranger suspension problems?
No. NHTSA lists no suspension recall for the 2002 Ford Ranger, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Ford Ranger suspension problems start?
Half of the complaints with a recorded mileage happened before about 94,000 miles, and 6% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.