Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
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. …
If I left the engine idle more than two minutes it would not pass the state emissions test. Now the emission light came on and it will not go off anymore. Almost got an accident vehicle will not drive over 20 MPH anymore. I must have the same problems of thousands of other people. I was told I have to change the heads on the engine because of poor quality cast iron heads that was used for like three years. My Ford truck is one of these years they had the issues. Now I have to spend thousands of dollars fixing it this is nonsense with the low miles I have on it. These fords should be recalled because of the safety issue. I have taken such good care of this truck and it still looks like brand-new I have to fix it! Please help!!!
After short drive, and shutdown engine would crank but not start. Towed to dealership. Next day truck started right up. Dealer could find no issues. Several weeks and 2000 miles later, problem occurred again. Found fuel inertia switch electrical connector melted. Fell apart when removing. Purchased new switch and electrical harness connector pigtail. Fortunately failure occurred after stopping and shutting down. Could cause a terrible accident if failure occurred at highway speeds. Something is causing an overheat condition in this switch/connector.
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.
While driving with passenger, the inertia switch can be easily unattached or loosened. This causes the truck to randomly die. If the manual vehicle dies while driving at high speed, in bad traffic, or turns requiring power steering, the vehicle can be dangerous.
Was driving and suddenly, my vehicle started to lose power. Was very scary because it was at night. Engine light came on and power was lost. Pulled off freeway into gas station. Checked fluids, etc.. Upon trying to leave, vehicle was sputtering with no compression. I did not think I was going to make it home. After a few minutes, I tried again, this time giving vehicle more gas. It seemed to do a little better. But, every time I had to slow down or stop for a stop sign or traffic light, vehicle was sputtering and acting like it was going to stall out. Was very nerve racking, as I was afraid of being rear ended by cars that were behind me. Now every time I slow down to where vehicle is in idle, it acts like it is going to stall out on me, which makes me very nervous. Had a mechanic install new plugs, new injector, coil package and vehicle is still doing badly and running very rough. …
On two occasions all power in this 2004 Ford Ranger vehicle shut down. The first time it would not restart and after checking the manual I reset the fuel pump shut off switch located beneath the glove box area and the vehicle restarted. 3/01/07, late evening, the vehicle lost all power on an expressway. Luckily, we were in the slow lane and could drift to the shoulder. I turned off the ignition before pushing the reset button for the fuel pump and it started. Ford motor customer care representative told me to take it to an assigned local dealer. The dealer said it will cost $59.95 for the diagnostic service and if this part is defective it is not within the 36,000 mile warranty and if Ford pays a portion it would be a very small amount. I have read two other on-line complaints, almost identical. One was listed under electrical problems and the other one was under engine problems. …
Two days ago I needed to replace my fuel filter. After doing so I needed to reset the "fuel shut off" switch. The problem appeared to be solved, but it wasn't!! Now my truck just stops running as I'm driving and I need to pull over and push the fuel switch again! When it stops all of my power is shut off...this is so frightening and extremely dangerous. It has happened twice just since I changed the filter two days ago. I'm afraid to even drive my truck now. It is obvious that the fuel shut off switch has a short in it. Now I am going to have to pay a mechanic to look at it and who knows how much that will run me? Shame on the Ford motor company, I've always trusted them but I guess it's time to switch...
Tl contact owns a 2004 Ford Ranger. The contact stated that the fuel pump shut off switch caused the vehicle to stall without prior warnings. As a consequence, her risk of a vehicle crash increased. The repair shop replaced the fuel pump shut off switch and installed a pressure reset locater kit. The failure mileage was 48,400 and the current mileage is 67,000. Updated 01/05/10 when the problem resurfaced again, the consumer was informed the switch was no longer available and he would need to install a relocator kit for the fuel pressure switch. The reset button is now located behind the passenger kick panel where the fuses are located. Updated 01/05/10.
Tl contact owns a 2004 Ford Ranger edge. The contact stated that he began to smell fuel. The vehicle was taken to an authorized dealership where the contact was informed that one of the fuel lines near the fuel tank burst. The contact stated that he did not drive the vehicle off road. The vehicle lost half a tank of fuel so the vehicle was towed to the dealership because the contact was afraid it might catch fire. The VIN was unavailable at the time of the complaint. The current and failure mileages were approximately 115,000.
Fuel System complaints in other Ranger years
Frequently asked questions
How common are fuel system problems on the 2004 Ford Ranger?
NHTSA has 21 complaints about the fuel & propulsion system of the 2004 Ford Ranger, 5% of the model year's 404 complaints. The component named most often is delivery › fuel pump (3 mentions).
Is there a recall for 2004 Ford Ranger fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Ford Ranger, though it has 10 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 2004 Ford Ranger fuel system problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 15% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to fuel & propulsion system 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.