Ford Ranger ball joint problems

Filed Oct 10, 2026 · Suspension · UT

On [XXX], my 2024 Ford Ranger Lariat, with approximately 25,000 miles, experienced a catastrophic front suspension failure while traveling at highway speeds. I suddenly felt what seemed like a tire blowout and was forced to pull onto the shoulder. Upon inspection, the driver’s-side front wheel was severely displaced and turned sideways. Immediately following the incident, I contacted Ford Motor Company for roadside assistance. Ford arranged towing through Murray Auto Body in Salt Lake City, Utah. Upon inspecting the vehicle, Murray Auto Body identified that the driver’s-side upper control arm had completely separated from the steering knuckle. Their technician indicated that the upper ball joint retaining nut appeared to be missing, allowing the ball joint stud to separate from the knuckle. Approximately two months earlier, Larry H. Miller Ford in Salt Lake City performed a warranty repair involving a leaking front strut. The repair took approximately three weeks due to backordered parts. After completing the repair, the dealership released the vehicle to my mother, who drove it home. The dealership subsequently contacted me, stating that they had forgotten to install several parts and that the vehicle was unsafe to drive. The vehicle was returned for additional corrective work. I am concerned that this failure may be related to the previous suspension repair or a manufacturing defect. Ford has issued safety recalls 24S64 (the federal safety agency 24V770) and 25S45 (the federal safety agency 25V310) involving missing or improperly tightened front upper control arm ball joint fasteners on certain Ford Rangers. My vehicle experienced a failure consistent with the conditions described in these recalls. This incident could have resulted in a serious or fatal accident. I am requesting an investigation into the cause of the suspension failure, including any connection to previous dealership repairs or known safety defects. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed May 19, 2026 · Suspension · FL

Newly purchased truck, less than 3 weeks old, with 987 miles. A few blocks from my home, the driver's side front control arm broke while going over a speed bump at approximately 4 miles per hour. The vehicle was towed to Walker Ford in Clearwater, Florida. Notes on the repair order stated that it looks like the control did not cure all the way, leading to the weakness. The vehicle was repaired. The tire was hanging off the vehicle, and hopefully did not damage any other components. The dealership stated that Ford requested the part back for inspection.

Filed Aug 9, 2025 · Driver assistance, Electrical · VA

VIN: [XXX] Recall data refreshed on Aug 09,2025 0 Unrepaired Recalls associated with this VIN Please Amber alert the following for NATIONAL BROADCAST the federal safety agency 2025 Ranger Safety Recalls* Inspect seat bolt presence and torque - recall is unable to be performed at this time. Please check the fsa landing page for more details. Recall incomplete Front upper control arm to knuckle ball joint loose or missing fastener Recall incomplete Instrument panel cluster configuration Recall incomplete INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Nov 23, 2022 · Suspension · NY

so I recently purchased this truck thinking it was all safe, the pictures were too good to be true thats for sure, When I brought the truck back the old owner even drove with me knowing what he just sold me. The next day I was so happy so I get it registered and insured and I was so eager to hope in and drive around in my new "safe" truck I also went out with my loved one and it sickens me that the old owner was ok with selling me a not so safe truck and I could have died if the frame bracket broke or the frame cracked while i was driving but when I started to look under I saw the problem and I was scared I saw that the upper control arm bracket mount was rusted and the strut tower as well it had a Hole forming and a crack on the strut tower. I also found out that there was a crack in the frame and i've looked up online and it seems that the frame and other components rust I don't know what to do. Im also a college student who is trying to get into the mechanic world and this scares me with how many trucks like this are out on the road.

Filed Dec 29, 2020 · Body, Steering · 127,642 miles · VA

I was driving was about 20 MPH and hit a small pot hole. I heard a loud pop bang noise and the left side of truck dropped about 2 or 3 inches. I thought the front end fell off. The frame is rusted so bad you can punch holes is the frame with a screw driver, the driver side torsion bar has collapsed due to rust on the frame that holds it in place, the crossmember to transmission is barley holding transmission up, the spare tire area is rusted in half, all main crossmembers are rusted in half and the frame is rusted in half behind fuel tank. Truck has 127k miles and the body body has little to no rust, upper and lower control arms are unsafe from rust. I do not understand how the body can be so good but frame and suspension is completely rusted to no return.

Filed Aug 19, 2020 · Brakes, Fuel system · 110,000 miles · ME

While driving the spare tire rack fell from the truck. Since the evap canister from the gas tank is attached to the spare tire rack it to was damaged with the canister being broken open while the rack scrapped on the road. After further inspection of the frame it was found that the gas tank support brackets had fallen completely off leaving only a thin strap supporting the gas tank. The frame also showed extensive corrosion on the front crossmember which supports the lower control arms. Brake line support tabs on the frame were also found to have completely separated from the frame at the weld. These are very dangerous situations and for highway safety and the trucks should be recalled. Thank you in advance for your attention in this matter.

Filed Aug 14, 2020 · Suspension · 110,000 miles · GA

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

Filed Dec 21, 2019 · Brakes, Steering · 57,000 miles · NH

We are original owners of a 2002 ford ranger xlt now with 57,000 highway miles, always garaged/washed/maintained, little driving in winter (mostly in summer), always ford maintained/serviced at same dealership, body/engine/transmission in great shape, will likely fail inspection this sping because frame and frame components are severely rusted out. - severe rust on the entire frame including both cross members (engine and transmission), arm bolt points and control arms. - frame also has severe rust down both sides to rear bumper, rear axle and differental, leaf springs and all mounts. - the passenger side stearing knuckle is delaminating. - all brake lines have failed while driving: first the rear brakes including all axle couplings and drum couplings; second the front brake lines failed at the disk brakes and rubber couplings. All brake tubes had to be replaced from the master cylinder to the wheels. - service manager is worried about front cross member failing under the engine, middle cross member failing under the transmission and the gas tank brackets/straps. - the frame and members and mounts must be replaced; the rest of the vehicle is mechanically sound. Service manager said no repair was possible to frame rust is so bad pictures can be provided and/or vehical inspected by the federal safety agency if desired. All brake lines and couplings performed around august 29, 2019.

Filed Dec 10, 2018 · Body · NY

Frame is rusting away. Front coil spring pockets cracking.frame near front control arms are rusted,and cracking.back frame spear tire bracket are gone.frame rusted back leaf spring shackels no matel frame for back bumper mount.

Filed Apr 7, 2018 · Body, Suspension · 111,150 miles · GA

Vehicle back bumper fell off due to excessive rust (while in motion). Ball joints, tie rods, upper and lower control arm brackets rusted out as well as holes in the frame (all identified while stationary).