Used car guide

2004 Ford Ranger: common problems and what to check

What gets flagged at MOT on 2004 Ford Rangers, from 1,439 tests in 2025, plus known faults and what to look at before you buy one.

1,439MOT tests in 2025
53%pass first time (all 2004 cars: 58%)
6,200typical miles a year
5.3×the usual rate for chassis rust or damage

What stands out

Parts flagged at MOT more often on 2004 Ford Rangers than on all cars registered in 2004.

  • Chassis rust or damage5.3× usual
    Ford Ranger
    21.3% All 2004 cars
    4%

    Failed outright at MOT: 5.4%, against 1.2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £150–£1,000 our estimate

    At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

  • Rigid brake pipes1.9× usual
    Ford Ranger
    32.1% All 2004 cars
    17.1%

    Failed outright at MOT: 5.8%, against 2.7% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £100–£400 our estimate

    At the viewing: Ask to see underneath, or check the MOT advisories: corroded brake or fuel pipes get worse every year and fail the MOT when they do.

  • Drive shaft (CV) joints2.4× usual
    Ford Ranger
    16.5% All 2004 cars
    6.8%

    Failed outright at MOT: 7.9%, against 2.9% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £60–£350 our estimate

    At the viewing: Drive slowly on full steering lock in both directions and listen for clicking. Look for split rubber boots behind the front wheels.

  • Rear fog light6.2× usual
    Ford Ranger
    9.3% All 2004 cars
    1.5%

    Failed outright at MOT: 9%, against 1.5% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £10–£80 our estimate

    At the viewing: Ask a friend to check every light while you work the switches: indicators, brake lights, fog lights and reversing lights.

  • Body structure rust or damage2.4× usual
    Ford Ranger
    8.3% All 2004 cars
    3.4%

    Failed outright at MOT: 1.9%, against 1% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £150–£1,000 our estimate

    At the viewing: Look underneath and along the sills for flaky rust or fresh underseal hiding it.

Better than most

Brake discs: 3.8% here, against 13.2% of all 2004 cars. Suspension arm bushes and joints: 4.5% here, against 9.5% of all 2004 cars.

By area

The share of 2004 Ford Ranger MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

  • Lights and electrics
    45% of testsRough price £10–£80

    At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

  • Brakes
    44% of testsRough price £150–£350

    At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

  • Suspension
    38% of testsRough price £120–£400

    At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

  • Rust and bodywork
    34% of testsRough price £150–£1,000

    At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

  • Tyres
    22% of testsRough price £70–£150

    At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

  • Driveshafts and joints
    17% of testsRough price £60–£350

    At the viewing: On full steering lock, drive slowly and listen for clicking from the front wheels.

Looking at a Ford Ranger?

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Other years

YearMOT testsMost flagged
2023513Tyres 13%
202215,140Tyres 23%
202115,990Tyres 22%
202011,398Tyres 20%
201914,131Tyres 20%
201813,682Tyres 21%
201710,386Tyres 21%
201610,171Tyres 22%
20156,022Suspension 30%
20143,878Suspension 34%
20132,787Suspension 40%
20121,790Suspension 43%
20111,415Brakes 43%
20101,295Lights and electrics 45%
20092,032Lights and electrics 48%
20081,798Lights and electrics 49%
20072,400Lights and electrics 48%
20061,997Lights and electrics 47%
20051,667Lights and electrics 46%
2003848Lights and electrics 44%
2002615Suspension 43%
2001468Brakes 44%
2000395Brakes 43%
1999165Suspension 45%

Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2004 Ford Rangers registered in 2004. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score