Ford Ranger

Failed injectors cause over-fuelling of individual cylinders and piston damage (crack in piston crown). The 2.2L Duratorq has a high rate of engine failures from this damage pattern, especially on early build years. Ford recommends premium diesel for this engine.

Symptoms: Knocking sounds, severe power loss, white or black smoke, engine failure

On the Ranger 2.2 TDCi the oil pump can fail causing immediate pressure loss. The result is crankshaft bearing and turbocharger damage. Unusual noises from the engine bay are the first sign.

Symptoms: Knocking from engine, oil pressure warning light, power loss, turbo noise

Coking injectors produce an uneven spray pattern, causing localised overheating and piston cracking. Mainly affects Transit 2006–2011; inspection every 50,000 km recommended.

Symptoms: Heavy smoking, engine misfiring, power loss, engine warning light, in the worst case engine failure due to cracked piston.

On the Ford 2.2 Duratorq TDCi (mainly Transit), carbonised injectors create uneven injection and damage pistons and combustion chambers. Excessive injection pressure under full load promotes piston pitting.

Symptoms: Smoke, rough running, power loss under load, injection quantity fault codes, in the worst case engine failure

The EGR system of the 2.2 Duratorq routes excessive soot particles into the centre cylinders under adverse conditions. Piston rings grind soot into the cylinder walls; compression loss possible from 100,000 km.

Symptoms: Power loss, heavy smoke, increased oil consumption, EGR fault codes, compression test shows pressure drop in centre cylinders

Failed oil pumps on the Ranger III 3.2L and 2.2L TDCi diesel engines cause unusual engine noises and can lead to severe bearing damage if ignored. Related to overdue oil changes or incorrect oil viscosity.

Nearly all Ranger III generations battle with rust, as factory underbody corrosion protection is inadequate. Poorly sealed edges and cavities promote early rust attack, especially on the chassis, sills and lower door edges.

The dual-mass flywheel on the 3.2L diesel produces characteristic vibration noises and fails prematurely. Vibration and rattling noises on cold start or when engaging the clutch are typical warning signs. Replacement often carried out together with the clutch.

On the Ranger III with the 3.2L diesel, faulty EGR valves and leaking intercoolers are known issues. EGR cooler and intake manifold cracks are further weak points. Regular EGR cleaning is recommended as a preventive measure.

The Ranger III's rear axle uses leaf springs that fatigue early with frequent load carrying or rough roads. Broken spring leaves and leaking shock absorbers from 80,000–100,000 km are typical workshop findings.