Front Suspension Leaf Spring Problems of Ford Ranger

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 NHTSA if desired. All brake lines and couplings performed around August 29, 2019.

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Rear leaf shackles replaced, rotted from frame, last Aug 2014 to pass inspection. This winter 2014-2015, the spare tire carrier frame rotted and fell from the vehicle, including the spare tire. Now, upon inspection of the bed appearing crooked, the drivers side frame in front of the drivers side front leaf spring mount is totally rotted. This has caused the gas tank mounts to the frame to break. It has also caused the bed to twist and the entire rear end of this vehicle is now only supported by the passenger side frame.

Rear leaf spring hangers/shackles rusted off as well as the front ones on the rear leaf springs. Spare tire carrier fell down dragging the spare tire across the road. One crossmember holding up the front of the gas tank is ready to go. Both gas tank straps rotted off. Toyota was made to fix these issues. Why not Ford? I work at a Toyota dealership replacing rotten frames on tundras, sequoias, and tacoma vehicles. There is no difference as both the frames for Toyota and Ford are built at the same factory if I am correct? the vehicle was being driven down the road all times the above listed failed. Some times on the highway, others in town. I do not feel safe selling this vehicle to another individual when it's ready to go.

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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.

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The rear leaf spring mounts, shackles and frame where it mounts have rotted through resulting in the leaf spring breaking loose from the frame. Also, the front cross member of the frame is disintegrating and shows signs of imminent failure.

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1993 Ford Ranger severe frame / suspension rust. On the rear leaf spring have had to replace front and rear hangers / shackles. The oem ones rusted completely through and let the leaf springs break loose. Only contact was on the spring eyelet hitting the bottom for the truck bed. Have also had to replace the cab mounts, also rusted completely through so that the rear of the cab was sitting on the frame. The frame is also showing severe corrosion. The farther back the worse it is.

Brought truck into service center for noise in front. Raised truck to inspect---- complete undercariage rusted beyond belief,front to rear bolts, nuts, brackets,frame, shocks, etc. Main concern is frame, brake lines --- had to have rear leaf spring support and bracket replaced because it was ready to break. Had shocks replaced because they looked like they could bust at any time. This is a truck with less than 32,000 miles --- body still looks great but underneath is questionable is there a recall or something I can fall back on ????.

Ford Ranger 1997 rear leaf spring mounts completely rusted away. Heard loud banging noise when driving. Inspected truck and found both driver and passenger rear spring mounts completely rusted away. Front spring mounts almost rusted away -near loss of rear axel and suspension !!! very dangerous failure without any warning. If had occured at hiway speed could have been total loss of rear suspension. Also dropping axel with leaf springs not good for any traffic following vehicle. Major safety problem as no other rust apparent on truck outside or elsewhere under truck. Inferrrior metal used for spring mounts which is apparently very prone to rust compared to rest of truck. Highly recommend all Ford Ranger owners be notified and advised to have spring mounts inspected before fatal accident occurs. Can not stress enough that there were no symptoms noted before failure, and no apparent rust on truck to indicate any problems.

The dealer fixed the leaf spring to correct what was a 3 inch lower left rear than the right rear. The truck fishtailed badby over any degree of rough road. It is slightly better since the spring has been replaced. But the dealer told me the leaning problem was still there. The said they contacted Ford and Ford told them the leaning was a problem with all 1998 Ford Rangers XLT and otherwise. There was a special shim created by Ford to correct the height difference in the rear. The dealer ordered the shim and I wait for it's arrival. Paint was bad in lower rear of cab also. The agreed to fix that. I need to know if this shim business is a safety problem. I don't want a shimmed new car. In the process of returning. I am not convinced they didn't know about it when it was sold to me as new & just hoped I wouldn't notice. I am checking with a body shop to see if the truck has been hit or damaged & repainted. It has tape on the body where the paint is bad! my plan is.

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