2002 FORD RANGER

Typical onset: 80,000-150,000 mi

Symptoms: Rattling on cold start that quiets after 10-15 seconds, Check engine light with cam/crank correlation codes (P0340, P0345), Sudden loss of power or no-start if guides break and chain jumps, Metal shavings in oil from disintegrating plastic guides

Fix: Requires timing chain cassette replacement on both banks, new chains, tensioners, guides, and often cam phasers. 8-12 hours labor. Many shops recommend doing water pump and oil pump chain simultaneously since front cover is off. If chain jumped and valves kissed pistons, you're looking at head work or full engine rebuild.

Estimated cost: $1,800-3,500

Typical onset: 100,000-180,000 mi

Symptoms: Delayed or harsh 2-3 shift when transmission is hot, Burnt ATF smell, dark red or brown fluid, Slipping under load, especially in overdrive, Whining or grinding noise from torque converter area

Fix: The internal oil cooler in the radiator is undersized for towing or hot climates. Cooler failure allows ATF and coolant to mix, destroying the transmission. Even without mixing, chronic overheating cooks clutch packs and seals. Rebuild requires 10-14 hours; must also install external auxiliary cooler and flush cooling system. Many techs recommend pre-emptive external cooler install on any survivor.

Estimated cost: $2,200-3,800

Typical onset: 60,000-120,000 mi

Symptoms: Clunking over bumps from front suspension, Excessive play when rocking tire at 6 and 12 o'clock, Visible grease boot tears or rust around ball joint, Wandering steering or pulling to one side

Fix: Ford used pressed-in lower ball joints that wear prematurely, especially in rust-belt states. Failure can cause wheel to separate from control arm while driving. Many techs replace entire lower control arm instead of pressing new joints (easier, similar cost). 2-3 hours per side. Alignment mandatory after replacement.

Estimated cost: $400-700 per side

Typical onset: 70,000-140,000 mi

Symptoms: Gear oil dripping from front of differential housing, Oil spots on driveway under rear axle, Whining or howling from rear end if fluid level drops significantly, Burnt gear oil smell after highway driving

Fix: Pinion seal hardens and leaks over time. Requires driveshaft removal, pinion nut removal while maintaining proper bearing preload (critical). Incorrect preload causes bearing failure. 2-3 hours labor. If caught early before fluid loss, differential internals are fine. If ignored until howling starts, expect full rebuild.

Estimated cost: $300-500

Typical onset: 60,000-110,000 mi

Symptoms: Check engine light with P0443, P0452, P0453 codes, Difficulty filling fuel tank (nozzle clicks off repeatedly), Fuel smell near driver's side of vehicle, Rough idle or stalling immediately after refueling

Fix: Ford's EVAP system components are fragile and exposed to fuel vapor corrosion. Purge valve sticks open or closed; tank pressure sensor reads incorrectly. Purge valve replacement is 0.5 hours, sensor requires dropping fuel tank (2-3 hours). Often both fail within 20k miles of each other. Won't prevent driving but causes emissions test failure.

Estimated cost: $200-350 for purge valve, $400-650 for tank sensor

Typical onset: 90,000-150,000 mi

Symptoms: Check engine light with P1537 or P1538 codes, Reduced power and poor acceleration below 3000 RPM, Rough idle or hesitation during light acceleration, No issues at highway speeds or wide-open throttle

Fix: Plastic IMRC actuators and linkage arms break or seize. Not safety-critical but kills low-end torque. Replacement requires upper intake manifold removal. 3-4 hours labor. Ford revised design multiple times; aftermarket Dorman units are hit-or-miss. Many owners delete system entirely with block-off plates if not in emissions-inspection state.

Estimated cost: $450-750