2004 FORD RANGER Recalls — Canada & USA

The 2004 Ford Ranger has 15 recalls, all centered on the frontal airbags: the inflators in both the driver and passenger airbags can rupture during deployment, sending metal fragments into the cabin and potentially causing serious injury. The airbag concerns span several related problems. The core issue is that both driver and passenger frontal airbag inflators can build excessive internal pressure and rupture, which prior repair attempts did not fully resolve, leading to multiple rounds of updated fixes. Trucks that were repaired under earlier recalls may also have had replacement inflators installed incorrectly, meaning the airbag may not inflate at all in a crash. Vehicles originally sold or registered in high-humidity regions face added risk, as prolonged heat and moisture can degrade the airbag propellant over time and increase the likelihood of rupture. There is also a separate structural concern: on regular cab models, a frame rail section that was not properly formed can puncture the fuel tank during a side-impact collision, creating a fuel leak that could ignite near any ignition source.