Manifold/header/muffler/tail Pipe Problems of Ford Ranger

2002 Ford Ranger. Consumer writes in regards to safety defect with plastic intake manifold the consumer stated recently while driving, suddenly and without warning as he left off the accelerator to make a turn , the engine rpm's dropped and the vehicle started idling erratically and almost slatted out completely. The consumer read on a website where a plastic plug could come out of the front of the plastic intake manifold. He removed the power steering pump and soon after, he discovered the plastic plug and about a 3/8 hole in the intake manifold. The hole caused the vehicle to loose vacuum in the system, therefore it was the cause of the erratic idle/stall. The consumer stated he welded the part back together after learning it would cost anywhere from $500-$1000 to replace.

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The contact owns a 1998 Ford Ranger. While driving approximately 40 mph, the vehicle began to shutter rapidly and the check engine light illuminated on the instrument panel. He drove approximately eight minutes to a local dealer and they stated that the cam shaft sensor became loose. The dealer tightened the clapping screw on the shaft sensor as a temporary repair. They also stated that the intake manifold needed to be replaced. The vehicle has not yet been completely repaired. The contact was informed that there was a service bulletin for his vehicle (item number 10000592). He filed a complaint with the manufacturer. The current and failure mileages were 60,300. Updated 04-09-08 the consumer stated there was a loose cam shaft sensor.

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The contact owns a 1999 Ford Ranger. A few years after the vehcile was purchased, the intake manifold failed. The dealer replaced the intake manifold sensor at the cost of $800. 00. The repair did not remedy the failure. The drivers seat was not leveled with the steering column because the seat does not have sufficient padding. As a consequence he could not properly view the road-way, which caused a vehicle crash. The vehicle was not repaired. The failure mileage was 160,000. The police report and the vehicle identification number was not available. There were no injuries. The current mileage was 220,000.

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Carbon monoxide leakage into cab of 1998 Ford Ranger caused severe sleepiness while driving to and from work and while at home. Each day for about a month I was experiencing dizziness, sleepiness and nausea. I had a small accident when I feel asleep while stopping for a red traffic light and ran into the back of another vehicle. I reported my dizziness and sleepiness to my supervisor who notified our medical department and they sent me home. I had a medical stress test performed; it was ok', a sleep study performed and the cardiologist increased my dosage of a beta blocker. I was finally released to return to work two months later. I had taken my vehicle to my local Ford dealer shortly after I was sent home and they reported there was no CO leaking into my cab. I tried discussing my problem with the Ford motor company's customer service department a couple of times, but they said the service technician could find nothing wrong and that's all they could do for the carbon monoxide was entering into my cab from the exhaust of other vehicles on the road. I finally found and bought a digital carbon monoxide detector which would read any level of CO detected. The first day I drove to work it indicated 18 ppm CO poison and another 16 ppm CO poison on the drive home after work which totaled around 34 ppm per day for over a month. I immediately went to my doctor and requested a blood gas test which indicated a high level of CO in my blood. It was confirmed by the pulmonary doctor that the sleepiness was caused by CO poisoning entering the cab of my truck. My truck is now parked in my drive way and has not been driven for over three months.

Xlt 4x4 4. 0l with only 38,500 sat for 2 days. When heading to work (1. 7 miles away) noticed no heat out of blower. . Noticed temperature gauge near top. Finsihed driving to work and temperature hit maximum, just before shutting off. Found steam coming out of oil filler cap. Dipstick was foamy. After tow to dealership, found out the intake manifold gasket had blown! the next day, dealership told me I need a new engine due to coolant in oil contamination. Ford/dealership is paying for 75% and I have to pay 25% ($1000) out of my pocket. This is because the extended warranty (4 year/60,000) ran out in July. Only 38,500 on odometer and this never should have happened! I cannot afford this! the loan was for 5 years ( July 2005).

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On starting engine hesitated ,almost stalled then raced with high rpm,while huge amounts of white thick smoke and heavy gasoline smell present. Truck stalled. Restarted same problem with the addition of a large black cloud of smoke from tail pipe on pushing accelerator. Throttle sticks causing surging. Dealer replaced throttle valve. Probelm persists. Brakes make grinding noise when applied,dealer could not replicate after 4 visits they finally ackowledge problem and had to do a complete brake job. Brakes are hard now and it appears that the anti locks do not engage. Rear slider leaks water into extra cab when it rains. Vibration heard from ex haust area,had to have the heat shield tightened. Noise has returned. /.

Due to design flaw, oil filter is located under manifold. While removing oil filter, the owner had his hand burnt by hot manifold. Yh.

The design of the filter is located under the hot manifold and below that filter is the hot solenoid and starter wires, consumer was injured/burned when changing filter, filter caught on fire when consumer dropped filter from being burned. Mjs.

Muffler fell apart.

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Tail pipe failed.