Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford Ranger owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Ford Ranger. The contact stated while doing routine maintenance at a local mechanic, the mechanic found that the rear sub-frame assembly was rusted through and needed to be replaced. The vehicle was not repaired. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 04V331000 (Structure) however, the VIN was not included. The manufacturer was informed of the failure and informed the contact that the vehicle was not included in the recall. The failure mileage was approximately 129,000.
Rear frame rusted and rotted..spare tire fell off entire evap can also..both sides rear frame shock and spring shackles rotted and broke off. Entire frame rotted and broke while driving ..on rear driver side frame rusted rotted and broke ..value of truck is not worth what estimates are ..gas tank hangers rusted and rotted many other pieces of frame rusted rotted through..truck is now unsafe to drive an probably unsellable due to broken rusted rotted frame..
July 19, 2015 re: NHTSA recall 04V331000 July 15, 2004. On June 18, 2015, berglund Ford of bedford, virginia refused to inspect my vehicle to determine if an improperly manufactured frame part exists that could rupture the gasoline tank during a side impact type of collision. 1. A visual inspection is the only method to determine if the recall hazard exists. 2. Ford's computer records can only indicate if an inspection has occurred. 3. It is impossible to determine logically if the recall hazard exists by using vehicle identification numbers. At the time of my request for an inspection, I was prepared to pay for the service because of the amount of time that has elapsed. Also, when I requested the inspection of the frame and fuel tank, I became aware of an air bag recall that had been recently published for my model of light truck. …
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. …
I purchased this 2004 Ford Ranger this past winter in hopes to pull my boat to the lake with it. Yesterday. I pulled my small bass boat to lake chickamauga and back which is about a 40 minute drive. It was a straight drive on a highway only going 50 MPH. When I got back my hitch, bumper and all was hanging. The frame is so rusted it broke in half. Had I not installed an after market hitch on this truck my whole bumper would have come off along with the boat that was attached and probably would have killed whoever was behind me ot not myself. I cant imagine what wouod have happened of I was on the interstate at higher speeds.the only thing holding it all together was the front bolt on the hitch when I got home. …
I was driving down the road while working one day last summer and the rear crossmember completely rotted away and fell off my truck taking the EVAP emissions canister with it when it went I was going 45 and luckily I saw it and heard it and no one was behind me but the frame in this vehicle has completely rotted away the crossmembers are all cracked or gone the frame rails are split and it will not pass inspection this year and I also lost the stair tire mount while driving the rear exhaust and the catalytic converter heat shield all while driving some on the highway I am disabled recently and can't afford a new vehicle or repairs and there's no reason this should have happened at all I need the vehicle to make my physical therapy and doctors appointment weekly please help if you can thank you
The rear part of the frame rotted bad..the spare tire hold fell off first..then not long after the rear bumper fell off on hiway ..after close inspection..the frame is brittle like a saltine cracker...plus the rear spring shacle rusted before an hed replaced...actually my son was driving my truck when the bumper fell off...taking rear tail pipe with it...when the spare tire holder fell off the day before..it took all the emission stuff along with it..this truck has only 150,000 miles on it ..the frame is rusted bad..never been in salt water..I have trucks older than this with solid frames when 25 years old....I have read on forums here after this happened and seems its a common thing with some year rangers,,,t4ruck is in a1 shape but now useless due to poor quailty steel
Tl* the contact owns a 2004 Ford Ranger. While attempting to have the vehicle inspected, rust was observed on the frame of the vehicle. The vehicle failed inspection. The vehicle was taken to an independent mechanic where it was diagnosed that the cross member and brackets failed and needed to be replaced. The vehicle was not repaired. The VIN was not included in NHTSA campaign number: 04V331000 (structure). The manufacturer was notified of the failure. The failure mileage was approximately 85,000. Updated 05/06/16 updated 06/16/16.
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.
Tl* Takata recall. The contact owns a 2004 Ford Ranger. Upon taking the vehicle to an independent mechanic for routine maintenance, the mechanic diagnosed that the bar that held the fuel tank in line had extensive rust and corrosion. The failure could cause the bar to fracture. The vehicle was not diagnosed nor repaired. The dealer and manufacturer were notified of the failure. The approximate failure mileage was 30,000. VIN tool confirms parts not available.
Related recalls
Structure › Frame and members › Underbody shields
On certain pickup trucks, the frame May have a center rail section flange that was not formed properly.
Remedy: Dealers will inspect the frame to determine whether the frame was incorrectly manufactured. If there is a problem, the vehicle will not be repaired. Ford and the dealer will replace the vehicle.
Body complaints in other Ranger years
Frequently asked questions
How common are body problems on the 2004 Ford Ranger?
NHTSA has 46 complaints about the body & structure of the 2004 Ford Ranger, 11% of the model year's 404 complaints. The component named most often is body (35 mentions).
Is there a recall for 2004 Ford Ranger body problems?
Yes — NHTSA recall 04V-331 (underbody shields, Jul 14, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2004 Ford Ranger body problems start?
Half of the complaints with a recorded mileage happened before about 85,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 3 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
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.