2004 Ford Ranger Problems & Recalls

2004 Ford Ranger Problems & Recalls

Looking to buy a used 2004 Ford Ranger? There are several owner-reported problems worth knowing about, including 3.0L engine misfires, fuel-pump inertia switch problems, unintended acceleration reports, and rust.

The 2004 Ranger also has an extensive Takata airbag recall history. Some trucks were included in multiple campaigns as Ford replaced earlier airbag inflators with updated parts.

Here are the problems and recalls to check when buying or owning a 2004 Ford Ranger.

Reported Problems

3.0L Engine Misfires and Stalling – Cylinder Head Problems

Some 2004 Rangers equipped with the 3.0L Vulcan V6 may experience rough running, misfires, and stalling. The check-engine light may come on, and the engine may run poorly at idle or under load.

Ford addressed this condition in Technical Service Bulletin 05-26-3. The problem can be caused by exhaust valve seat recession, resulting in a loss of compression. If the exhaust valve is identified as the cause, the bulletin calls for replacing both cylinder heads with updated service parts.

This is an important issue to investigate when considering a 2004 Ranger with the 3.0L engine.

Crankshaft Pulley Failure

A few owners have reported crankshaft pulley failures. The problem may start with a squeaking or chirping noise before the pulley separates at its rubber isolator.

If you hear an unusual noise coming from the front of the engine, inspect the crankshaft pulley and harmonic balancer for separation, wobble, or deterioration.

Timing Chain Guide Wear

The plastic timing chain guides can wear or break. Listen for rattling from the timing chain area, particularly during startup. A timing chain problem should be investigated before it leads to more extensive engine damage.

Automatic Transmission Shifting Problems

A few owners have reported automatic transmission problems, including:

• Clunking when shifting
• Jumping in and out of gear
• Slipping during the 1-2 shift

During a test drive, pay attention to delayed engagement, harsh shifts, slipping, and unexpected changes in gear.

Fuel Pump Inertia Switch Problems

Numerous owner reports describe the fuel pump inertia cutoff switch activating unexpectedly and shutting off fuel delivery to the engine.

The switch is designed to interrupt power to the fuel pump after an impact. However, owners have reported situations where the engine shuts off without a collision.

If a Ranger stalls unexpectedly, check the inertia switch and its electrical connections as part of the diagnosis. Don’t automatically assume the fuel pump itself has failed.

Unintended Acceleration or Lurching While Braking

Numerous reports describe the truck lurching forward or accelerating while the driver is braking.

This is a serious complaint, but the reports do not establish one confirmed cause or prove that every 2004 Ranger has this problem. Any unexpected throttle response should be diagnosed before the truck is driven again.

Windshield Wiper and Electrical Problems

Electrical complaints include:

• Intermittent windshield wiper operation
• Wipers coming on when the headlights are switched on
• The horn and windshield wipers activating when the headlights are turned on

If these symptoms occur together, inspect the related electrical circuits, switches, wiring, and connections rather than replacing individual components without diagnosing the cause.

Rear Window Comes Loose or Leaks

Several owners have reported problems with the rear window becoming loose or popping out. A loose rear window can also allow water to enter the cab.

One reported explanation involves the seat backs being pushed against the rear window. Check the rear glass installation and make sure the seats are not pressing against it. Look for water stains, damp carpet, or other signs of water intrusion behind the seats.

Rear Pinion Seal Leaks

A leaking rear differential pinion seal has also been reported. Inspect the area around the driveshaft yoke and differential for oil leakage. A leak that goes unnoticed can eventually lead to low differential fluid.

Airbag Warning Light and Airbag Deactivation

Owners have reported airbags failing to deploy in a crash. There are also concerns involving the passenger airbag on/off switch.

The indicator light in the airbag switch module is reported to be hardwired into the circuit board. If the bulb burns out, the module may deactivate the driver and passenger airbags.

If the airbag warning light is on, or the passenger airbag status indicator does not operate correctly, have the supplemental restraint system diagnosed. Do not assume the airbags are operational simply because the warning light is off.

The 2004 Ranger is also covered by several Takata airbag recalls, which are described below.

Steering Column Rattle

A rattle from the steering column has been reported. Listen for noises when turning the steering wheel or driving over rough pavement. Have the steering column and related components inspected if the noise is present.

Bed Rust and Water Leaks

Owners have reported rust developing underneath the bed, particularly in the area where a factory pad was applied near the muffler. Moisture, road debris, and exhaust heat can contribute to corrosion in this area.

There are also reports of water leaking into the cab around the rear brake light. Inspect the headliner and rear cab area for water stains or dampness.

Frame, Bed Mount, and Rear Suspension Rust

Rust is an important inspection item on the 2004 Ranger. Reports include:

• Excessive frame rust
• Front bed mounts rusting out
• Rear spring hanger and shackle corrosion
• Spare tire carrier rusting enough for the spare tire to fall off

Inspect the frame carefully, especially around the rear spring hangers, shackles, bed mounts, and areas where dirt and moisture collect. Check the spare tire carrier as well.

Don’t just look at the visible sides of the frame. Serious corrosion can develop around mounting points and on surfaces that are difficult to see.

Paint Peeling

Paint peeling from the front portion of the roof has also been reported. Inspect the roof and other exposed body panels for peeling, fading, or corrosion beneath damaged paint.

2004 Ford Ranger Recalls

The 2004 Ranger has an extensive Takata airbag recall history, along with recalls involving the frame and replacement lighting parts.

Some of the airbag campaigns superseded earlier recalls or addressed the possibility that replacement inflators were installed incorrectly. A truck that received an earlier repair may still have needed a later campaign.

23V306 – Passenger-Side Airbag Inflator Installed Incorrectly

Ford recall 23S08 covers certain 2004–2006 Rangers that previously received replacement passenger-side airbag inflators under an earlier recall.

The replacement inflator may have been installed in the incorrect orientation. If installed incorrectly, the passenger airbag may not inflate properly during a crash, increasing the risk of injury.

Dealers will inspect the inflator and reinstall it correctly if necessary, free of charge. This campaign expands and replaces the earlier 23V125 recall.

NHTSA Recall Information – 23V306

21V076 and 21V081 – Airbag Inflator Replacement Parts

These campaigns concern certain vehicles that may have received defective Takata airbag inflators as replacement service parts.

Some dealers and collision repair shops had received obsolete replacement inflators. Ford could not determine whether all of those parts had been installed in vehicles.

The campaigns address the possibility that an affected Ranger received one of these replacement inflators during a subsequent airbag repair. They do not apply to every 2004 Ranger.

Check the VIN to determine whether a specific truck is affected.

NHTSA Recall Information – 21V076

NHTSA Recall Information – 21V081

17V787 – Driver-Side Airbag Inflator

Ford recall 17S42 covers certain 2004–2006 Rangers equipped with Takata driver-side frontal airbag inflators.

The inflator may rupture during deployment, sending metal fragments into the passenger compartment and potentially causing serious injury or death.

This campaign provided a final remedy for affected vehicles. Some Rangers had previously received an interim replacement and may have needed another repair.

NHTSA Recall Information – 17V787

17V788 – Passenger-Side Airbag Inflator

Ford recall 17S42 also covers certain 2004–2006 Rangers equipped with Takata passenger-side frontal airbag inflators.

The inflator may rupture during deployment, potentially sending metal fragments into the vehicle and causing serious injury or death.

This campaign provided a final replacement remedy for affected passenger-side inflators. Some vehicles that received an earlier interim repair may have needed another replacement.

NHTSA Recall Information – 17V788

16V036 – Driver-Side Airbag Inflator

Ford recall 16S03 covers certain 2004–2006 North American-built Rangers equipped with Takata driver-side frontal airbag inflators.

The inflator may rupture during deployment, sending metal fragments into the vehicle and potentially causing serious injury or death.

This recall superseded the earlier regional driver-side airbag recall 14V343 for the affected vehicles.

NHTSA Recall Information – 16V036

15V322 – Passenger-Side Airbag Inflator

Ford recall 15S22 covers certain 2004–2006 Rangers equipped with passenger-side Takata frontal airbag inflators.

Moisture intrusion can cause the inflator to rupture during deployment, sending metal fragments into the passenger compartment and potentially causing serious injury or death.

This recall partially superseded the earlier regional passenger-side airbag recall 14V787.

NHTSA Recall Information – 15V322

11V352 – Multifunction Switch / Lighting

This recall involves certain 2011 Ford Rangers and replacement service parts distributed for certain 2004–2011 Rangers.

A switch slider may deform and cause the turn signals, tail lights, hazard flashers, or brake lights to fail to activate.

The factory-built vehicle portion of this recall does not apply to a 2004 Ranger. However, a truck could be affected if it received an affected replacement service part.

NHTSA Recall Report – 11V352 (PDF)

09E025 and 06E065 – Aftermarket Replacement Lighting

There were recalls involving certain aftermarket replacement combination lamp assemblies sold for use on the 2004 Ranger and other vehicles.

The replacement lamps did not meet federal lighting requirements because they lacked required amber side reflectors. These were recalls of aftermarket replacement parts, not the original factory-installed Ranger lighting.

If the truck has aftermarket headlamps, corner lamps, or bumper lamps, check that they meet applicable lighting requirements.

04V331 – Frame Rail / Fuel Tank Clearance

Ford recall 04S19 covers certain 2004 Ranger regular-cab pickup trucks built at the Twin Cities Assembly Plant between June 2 and June 25, 2004.

The frame rail supplier may have produced frames with a center rail flange that was not formed properly. The flange could contact and abrade the fuel tank over time, potentially causing a fuel leak.

Ford instructed dealers to inspect the frame near the fuel tank. If an improperly formed flange was found, Ford would replace the vehicle.

Approximately 1,395 vehicles were involved.

NHTSA Recall Report – 04V331 (PDF)

Technical Service Bulletins (TSBs)

Technical Service Bulletins (TSBs) for the 2004 Ranger are official communications between Ford & their dealerships that describe processes for troubleshooting or fixing certain common problems. All vehicle manufacturers are required by U.S. law to make their TSBs available to the public.

For a list of the TSBs for the 2004 Ford Ranger check out: 2004 Ford Ranger TSBs

What to Check When Buying a Used 2004 Ford Ranger

When inspecting a 2004 Ranger, pay particular attention to:

• 3.0L engine: Check for rough idle, misfires, stalling, and evidence of cylinder head repairs related to TSB 05-26-3.
• Engine noises: Listen for crankshaft pulley chirping and timing chain rattling.
• Fuel inertia switch: Ask whether the truck has a history of unexpected stalling or fuel pump shutoff.
• Automatic transmission: Check for harsh shifts, slipping, clunking, or unexpected gear changes.
• Unintended acceleration: Make sure the throttle responds normally and investigate any history of lurching while braking.
• Windshield wipers and electrical system: Test the wipers, headlights, horn, and washer system together.
• Rear window: Check for loose glass, water leaks, and signs that the seats have been pushing against the window.
• Airbag system: Check the warning lights and passenger airbag indicator. Verify that all applicable Takata recalls have been completed.
• Frame and bed mounts: Inspect the frame, front bed mounts, rear spring hangers, shackles, and spare tire carrier for serious corrosion.
• Brake and fuel tank area: On a regular-cab truck built during the 2004 recall production period, verify whether the frame inspection under recall 04V331 was completed.

Check for Open Recalls

A model-year recall list does not tell you whether a specific truck has had its recalls completed. Use the VIN to check for outstanding recall repairs.

• NHTSA VIN Recall Lookup
• Ford Recall Lookup

Because of the Takata airbag history, checking the VIN and confirming the final repair history should be a priority before buying or driving a 2004 Ranger.

Related Ford Ranger Information

• 1983–2011 Ford Ranger Buyer’s Guide
• The Ranger Station Technical Library
• The Ranger Station Forums
• Ford Ranger Brochures