2004 Ford Ranger problems

What is wrong

Ford Motor Company (Ford) is recalling certain 2004-2006 Ranger vehicles that received replacement front passenger air bag inflators under a previous recall. The replacement front passenger air bag inflators may have been installed incorrectly.

Risk

An incorrectly installed inflator may not properly inflate the passenger air bag, increasing the risk of injury during a crash.

Remedy

Dealers will inspect and reinstall the front passenger air bag inflator, as necessary, free of charge. Owner notification letters were mailed May 22, 2023. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 23S08. This recall expands and replaces previous recall number 23V‑125.

Recall number 23V306000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2004-2006 Ranger vehicles that received replacement front passenger air bag inflators under a previous recall. The replacement frontal passenger air bag inflators may have been installed incorrectly.

Risk

An incorrectly installed inflator may not properly inflate the passenger air bag, increasing the risk of injury during a crash.

Remedy

Dealers will inspect and reinstall the front passenger air bag inflator, as necessary, free of charge. Owner notification letters were mailed April 5, 2023. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 23S08. This recall has been fully superseded by recall 23V‑306.

Recall number 23V125000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2004-2006 Ranger vehicles that may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.

Risk

In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 21S05.

Recall number 21V076000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain 2005-2014 Mustang, 2004-2011 Ranger, 2009-2011 Mercury Milan, 2006 Ford GT, 2008-2012 Fusion, 2007-2010 Edge and Lincoln MKX, and 2009-2010 Lincoln MKZ vehicles. These vehicles may be equipped with a driver or passenger frontal air bag inflator used as a replacement service part, that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.

Risk

In the event of a crash necessitating deployment of the frontal air bag, an inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will inspect the driver and passenger air bag module, and replace either the module or the inflator, if necessary, free of charge. The recall began March 17, 2021. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 21S05.

Recall number 21V081000 · Recall details

What is wrong

Ford Motor Company (Ford) is superseding a previous recall for certain 2004-2006 Ford Ranger trucks to implement a final repair. Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the driver's frontal air bag inflator with an alternate inflator, free of charge. The recall began January 16, 2018. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 17S42. Note: This recall supersedes recall 16V‑036 which was an interim repair. Vehicles that received a replacement air bag inflator under the previous campaign need to return to a dealer to have an alternate inflator installed.

Recall number 17V787000 · Recall details

What is wrong

Ford Motor Company (Ford) is superseding a previous recall for certain 2004-2006 Ford Ranger trucks to implement a final repair. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants, potentially resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicles until the repair has been performed. Ford will notify owners, and dealers will replace the passenger's frontal air bag inflator with an alternate inflator, free of charge. The recall began January 16, 2018. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 17S42. Note: This recall supersedes recall 15V322 which was an interim repair. Vehicles that received a replacement air bag inflator under the previous campaign need to return to a dealer to have an alternate inflator installed. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 17S42.

Recall number 17V788000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain model year 2004-2006 Ranger vehicles manufactured March 24, 2003, to May 4, 2006. Upon deployment of the driver side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will replace the air bag inflators, free of charge. The recall began February 26, 2016. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 16S03. Note: This recall supersedes 14V‑343 and only applies to Rangers manufactured in North America.

Recall number 16V036000 · Recall details

What is wrong

Ford Motor Company (Ford) is recalling certain model year 2004-2006 Ranger trucks manufactured March 24, 2003, to May 4, 2006. The affected vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Remedy

Ford will notify owners, and dealers will replace the front passenger air bag inflator, free of charge. The recall began on December 4, 2015. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 15S22. Note: This recall partially supersedes recall 14V‑787.

Recall number 15V322000 · Recall details

What is wrong

Ford is recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250, f-350, f-450, and f-550 trucks for failing to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." the multi-function switch was shipped with a subcomponent (slider) that may experience deformation. A multi-function switch with a deformed slider may malfunction causing the turn signal, tail lights, hazard warning signal flashers and/or brake lights not to activate.

Risk

Non-functioning lights could increase the risk of a crash.

Remedy

Dealers will replace the switches free of charge. The safety recall began on august 15, 2011. Owners may contact ford motor company customer relationship center at 1‑866‑436‑7332.

Recall number 11V352000 · Recall details

What is wrong

On certain pickup trucks, the frame may have a center rail section flange that was not formed properly.

Risk

In the event of a side impact crash, the frame rail scould puncture the fuel tank, resulting in a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire.

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. The recall began on july 19, 2004. Owners should contact ford at 1‑800‑392‑3673.

Recall number 04V331000 · Recall details

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

EA15001

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

PE14016

This pe was opened based on technical service bulletin (tsb) #05-6-19 issued by ford motor company and service bulletin #09-008/5 issued by mazda motor corporation to address concerns of the center high mounted stop light (chmsl) wiring harness chaffing. The tsb's affected the ford super cab and mazda cab plus vehicles only.service technicians contacted the ford hotline because it was difficult for the technicians to diagnose and locate the cause of the inoperative brake lights.ford and mazda issued the tsb's to aid technicians in the identification and repair of the wire chafe condition.of all warranty claims submitted to ford for brake lamp failure, ford identified only 120 that were related to wire chafe near the chmsl, and most (115 of the 120) were reported for the super cab chmsl. Odi's review of ford's warranty claims and complaint data reveals a declining trend for the super cab and that trend closely parallels the trend for the standard cab as well.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.

PE05066