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 2004 Ford Ranger owners, lightly cleaned up (personal details are redacted by NHTSA).
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. …
While driving my 2004 Ford Ranger, only had 60,000 km's on it, down the highway at about 80 kmph, the left side of the rear axle broke, as I was going over a bridge causing loss of control and striking a bridge, tearing up 20 feet of guard rail and railing 5 times. The air bags also did not deploy as they should have as front bumper hit bridge rail directly. Was cleaned up by police and tow company. Insurance company had the vehicle and believe they May have scraped it as they did not want it on the road again.
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.
The front subframe where the lower control attaches has separated or broken due to rust. I was headed home from work, under normal driving conditions, with no extra load on vehicle. I hit a bump going thru parking lot n heard a pop. I had stopped at gas station n seen that driver side wheel n tire were not straight up n down, it was at a degree or angle. Got underneath n seen that subframe was rusted all the way thru where lower control arm was attached
Frame rusted out on passenger side behind front leaf sprinf mount. Also the cross member holding fuel tank where it connects to the frame is rusted out. Its only the back half of the truck rusting out this bad. Where the spare tire goes is also completly rusted out and fell off. This happened while driving on smoothly paved roads to and from work
The right rear frame is badly rotted to the point where the leaf spring broke off the frame. That allowed the body to come in contact with the gas tank and shorted out one of the transmission wires. The front bumper is rusted out on the passenger side corner. The rusted frame is the big issue.
Tranny dropped down causing vibration and vehicle pulled off road and towed. Found 2 cross supports rotted and separated also.body of truck is like new. Frame unsafe. Toyota recalled for this same reason. Ford needs to be held responsible also.
The rear bumper frame has rusted out and detached from vehicle. Loading brush into truck bed, stepped on bumper, and it collapsed. Checking the rear frame, springs, and suspension shows extended rust, making the vehicle unsafe to drive.
On March 06,06. Exactly 2 months after taking delivery of a "quality checked preowned " 2004 Ford Ranger pickup from a local dealership while driving to work at 4:30 am s/b on the I 15 suddenly, without warning the vehicle veered hard left slammed into the center gaurdrail then flipped and rolled causing vehicle to be a classified as a total loss by insurance co. After inspection of vehicle I was drawn to the fact that the front left wheel assembly including brake rotor and hub were detached from vehicle and after further inspection it appears that the wheel bearing retaining assembly is at fault. …
Tl* the contact owns a 2004 Ford Ranger. The contact stated that while driving approximately 25 MPH, the rear shackles failed. The vehicle was taken to a dealer where it was advised that there was corrosion around the control arm where it was mounted to the frame. The vehicle was repaired. The manufacturer was notified of the defect. The approximate failure mileage was 61,000. Updated 06/18/14 updated 06/24/2014 the consumer stated the repair technician advised the steel rim was leaking at the weld seam where the two halves joined. The spare tire rim and holding device were rusted and rendered the tire could unable to be removed. The vehicle was repaired. Updated 06/24/2014
Suspension complaints in other Ranger years
Frequently asked questions
How common are suspension problems on the 2004 Ford Ranger?
NHTSA has 29 complaints about the suspension of the 2004 Ford Ranger, 7% of the model year's 404 complaints. The component named most often is front › wheel bearing (3 mentions).
Is there a recall for 2004 Ford Ranger suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 83,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 3 injuries to suspension 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.