Ford Ranger

Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.

Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode

Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.

Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction

The wet timing belt running in the oil bath disintegrates and blocks the oil pump strainer with debris. The engine dies from oil starvation — bearings, crankshaft, camshaft, and turbocharger are destroyed.

Symptoms: No warning: oil pressure drops, engine runs rough, then total failure. The belt itself may look visually intact.

The turbocharger on the 2.0 EcoBlue sometimes fails before 50,000 km. Cause: belt particles in the oil circuit or excessively long oil change intervals block the oil supply to the turbo bearings.

Symptoms: Whistling noise during acceleration, noticeable power loss, blue smoke. Turbo warning light may not illuminate.

A design-inherent uneven distribution of EGR exhaust gases leads to excessive soot ingestion into the centre cylinders. Soot particles cause abrasive wear via the piston rings — compression loss and engine replacement required.

Symptoms: Rough idle, increased oil consumption, white or black smoke, high fuel trim correction values in fault memory.

The NOx sensor in the SCR exhaust aftertreatment system fails prematurely. Fault code P20EE is typical. AdBlue consumption increases measurably as the system reverts to a base map. Sensor replacement is relatively inexpensive.

Symptoms: Check engine light P20EE, increased AdBlue consumption, occasional no-start after many km

Faulty injectors prevent complete DPF regeneration; the filter clogs before 100,000 km. Ford has replaced affected injectors and DPFs free of charge under recall up to 160,000 km.

Symptoms: DPF warning light, increased fuel consumption, engine judder, limp mode active.

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.