Ford Ranger PJ: common faults & what to check

Symptoms to notice

• Rough or lumpy idle, especially noticeable when the engine is cold
• Engine warning light, or a warning light that flashes under acceleration
• Stumble, hesitation or a hollow flat spot when you accelerate hard
• Ticking or tapping from the top of the engine
• Loss of power with the engine running on fewer cylinders than it should

What to check

1. 1.Start the engine from stone cold yourself and stand beside it with the bonnet up for the first two minutes, listening for an even idle - a V6 should settle to a smooth, steady beat, and a rock or shake through the body at idle is worth stopping the sale over.
2. 2.Watch the tachometer needle at idle for any dip or flutter.
3. 3.Hold your hand near, not on, the exhaust tip and feel whether the pulses are even.
4. 4.Drive it hard enough to load the engine properly, ideally a long uphill run in a lower gear, and feel for any stumble, hesitation or flat spot, and watch for the engine warning light coming on or flashing.
5. 5.Listen at the top of the engine for a tick or tap that keeps time with engine speed.
6. 6.Ask whether the engine has ever been replaced, whether the spark plugs have been changed early, whether there is any dealer paperwork mentioning misfires or SSM 51979, and ask to see the full service history.
7. 7.If a workshop inspection is possible: request a compression test and a cylinder leakage test on all six cylinders and a read of stored misfire counters.

Symptoms to notice

• Hard start or extended cranking before the engine fires
• Rough idle with injector ticking becoming uneven
• Power loss or engine stalling under acceleration load
• Metal shavings or black residue visible in the fuel filter bowl
• Complete sudden engine failure with no restart possible

What to check

1. 1.Check for any history of hard start, long crank times, or engine stalling under load — early warning signs before full pump failure.
2. 2.Request fuel system service records and ask if the vehicle has ever consumed any fuel additives.
3. 3.Listen at idle for uneven injector ticking or misfiring.
4. 4.On PX3 Rangers with high kilometres (above 80,000 km) and no pump replacement history, treat this as a latent risk.

Symptoms to notice

• Engine stalling suddenly while driving with no prior warning
• Rattle or metallic tapping from the front of the engine, particularly on start-up
• Engine warning light with rough running or a misfire
• Engine that cranks but will not start after a stall

What to check

1. 1.The decisive check here is paperwork, not the driveway.
2. 2.Ask the seller for the vehicle identification number and check the recall status against REC-006341 on the Australian government recall listing, or ask Ford New Zealand to confirm against the VIN, before you hand over any money - the work is free and a dealer can tell you in minutes whether it has been done.
3. 3.Ask to see the service history and look for a dealer invoice or field service action entry referring to the camshaft sprocket.
4. 4.Ask whether the engine has ever stalled while driving, whether it has ever been towed anywhere, and whether the engine warning light has come on.
5. 5.Start the engine from cold yourself and listen at the front of the engine for a metallic rattle or tap in the first few seconds, then again once it is warm.
6. 6.On the test drive listen for any misfire or hesitation under load and watch the dash for warning lights.
7. 7.Treat a seller who cannot or will not give you the VIN as a reason to walk away.

Symptoms to notice

• Sudden engine stall with no warning
• Unusual rattling or slapping from timing cover area
• Engine cranks but will not fire after belt failure
• Hard starting or intermittent misfires preceding failure
• Timing belt service overdue past 120,000 km or 6 years

What to check

1. 1.Check service records for timing belt replacement at or before the 120,000 km or 6-year mark.
2. 2.Listen for a faint tensioner rattle at cold start that disappears when warm.
3. 3.Verify tensioner and idler pulleys were replaced simultaneously with the belt.
4. 4.If a workshop inspection is possible: Remove the timing cover inspection plug and examine belt condition for cracking, glazing, or frayed edges.

Symptoms to notice

• Loud high-pitched whine or metal-on-metal noise from the engine under acceleration, distinct from normal turbo spool sound
• Significant power loss under load with black or blue-white smoke and an underboost fault code logged

What to check

1. 1.Check the intercooler inlet and outlet hoses for oil residue — some blowby is normal but heavy oiling indicates turbo seal failure.
2. 2.Listen for a high-pitched whine or chirp from the turbo side of the engine under boost.
3. 3.Check for fault codes P0299 (turbocharger underboost) or P0234 (overboost).
4. 4.Inspect oil change history carefully — the 2.0 BiTurbo requires low-SAPS 5W-30 oil and is sensitive to extended intervals.

Symptoms to notice

• Rhythmic metallic ticking or clatter from the valve cover area at idle, distinct from normal diesel combustion noise
• Injector seal leak evidenced by carbon tracking or oil/soot deposits around the injector clamp area on the cylinder head

What to check

1. 1.Ask workshop whether injectors have been removed previously and what treatment was applied on reinstallation (copper anti-seize on the clamp bolt is correct procedure).
2. 2.Check service history for any injector replacements.
3. 3.Listen for injector clatter at idle — a ticking or rattling from the top of the engine that changes with rpm indicates worn nozzle needles on high-mileage units.

Symptoms to notice

• Burning grass smell after off road use
• Scorched debris packed around the exhaust

What to check

With a phone torch look under the ute along the exhaust for packed dry grass or scorch marks. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2017/16479 (exhaust vegetation) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Symptoms to notice

• Difficult cold start or unstable idle
• Fault codes or irregular readings when scanned

What to check

1. 1.Check for oil leaks around valve covers, sump and gaskets.
2. 2.Inspect coolant condition and level.

Symptoms to notice

• Hard starting particularly when engine is hot
• Progressive loss of power under load above 2500 RPM
• Engine stumble or hesitation on accelerating from low speed
• Excessive black smoke under hard acceleration
• P0087 (fuel rail pressure too low) or P0191 fault code stored

What to check

1. 1.Scan for fuel rail pressure fault codes before driving.
2. 2.Ask specifically whether the vehicle has ever been run very low on fuel or run dry.
3. 3.Check for any history of injector replacement or fuel system work which may indicate a contamination event.
4. 4.Listen for injector chatter or rattling at idle, which can indicate metallic debris in the fuel rail.

Symptoms to notice

• Evidence of engine wear or deterioration
• Warning light or abnormal behaviour noted during operation

What to check

1. 1.Check for oil leaks around valve covers, sump and gaskets.
2. 2.Inspect coolant condition and level.

Symptoms to notice

• Evidence of engine wear or deterioration
• Warning light or abnormal behaviour noted during operation

What to check

1. 1.Check for oil leaks around valve covers, sump and gaskets.
2. 2.Inspect coolant condition and level.

Symptoms to notice

• Metallic rattling or chain slap noise from the transfer case area on cold startup or during 4WD engagement
• Difficulty engaging or disengaging 4WD HIGH or 4WD LOW, with grinding or reluctance from the transfer case motor

What to check

Engage and disengage 4WD HIGH and 4WD LOW multiple times and listen for clunking, grinding, or delayed engagement. With the vehicle stationary and the transfer case in 4WD, listen for chain rattle with the engine at idle. Check the transfer case oil level and condition — metallic particles in the oil indicate chain or gear wear. Ask whether 4-wheel drive has been used regularly and whether the transfer case oil has been changed.

Symptoms to notice

• DPF warning light illuminated on the dashboard, often accompanied by a request to drive at highway speed for 20-30 minutes
• Reduced power (limp mode) and increased fuel consumption as the ECU restricts output to protect the blocked filter

What to check

1. 1.Check for fault codes P2002 (DPF efficiency below threshold) and P244A/P244B (DPF differential pressure).
2. 2.Ask the seller about typical driving patterns.
3. 3.Inspect the exhaust for signs of incomplete regeneration (soot staining around the DPF canister).
4. 4.If a workshop inspection is possible: Connect an OBD scanner and read DPF soot load percentage — anything above 70 percent indicates impending forced regeneration or blockage.

Symptoms to notice

• White or blue-white exhaust smoke that persists after the engine has fully warmed up
• Coolant level dropping progressively with no external leaks, puddles, or oil contamination in the coolant

What to check

1. 1.Check the coolant reservoir level against service history — unexplained drops without visible external leaks suggest internal loss.
2. 2.Inspect the intake manifold for a white or milky residue on internal surfaces.
3. 3.Run the engine to operating temperature and observe exhaust: persistent white steam after warm-up indicates coolant combustion.
4. 4.Check for fault codes P0401 (EGR flow insufficient) alongside unexplained coolant loss.

Symptoms to notice

• Evidence of engine wear or deterioration
• Warning light or abnormal behaviour noted during operation

What to check

1. 1.Check for oil leaks around valve covers, sump and gaskets.
2. 2.Inspect coolant condition and level.

Symptoms to notice

• Visible coolant residue or rust staining on the exterior of the engine block, particularly at the sides or rear of the cylinder block
• Slow unexplained coolant loss with no visible radiator, hose, or head gasket leak, and no white exhaust smoke

What to check

1. 1.Inspect the sides and rear of the engine block for orange rust staining or dried coolant residue (pink or green crystalline deposits depending on coolant type).
2. 2.Check around the bell housing area at the back of the block — coolant tracking down here is often mistaken for a gearbox leak.
3. 3.Check coolant condition: brown or rusty coolant indicates inhibitor depletion and accelerated internal corrosion.
4. 4.Confirm coolant change history.

Symptoms to notice

• Battery or charging warning on the dash
• Car jolts to a stop at walking pace
• Gear display jumps to P while rolling slowly

What to check

1. 1.Ask the seller whether Ford has done the Park-shift software recall, and whether a second recall letter arrived in 2026.
2. 2.Ask to see the service book or dealer invoice listing the recall work.
3. 3.Watch the dash at start-up for a battery or charging warning.
4. 4.On the test drive, creep slowly in a car park and make sure the car never drops into Park on its own.
5. 5.If a workshop inspection is possible: a Ford dealer can check the VIN against both recall campaigns and confirm the PCM software level.

Symptoms to notice

• Cruise does not switch off with the button or brake pedal

What to check

On the test drive, on a safe open road, set the cruise and check it cancels with the cancel button and with a light touch of the brake pedal. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2011/12307 (cruise control) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Symptoms to notice

• Sudden power loss with the engine entering limp mode at 1,500 rpm maximum, dashboard engine management light illuminated
• Engine management light triggered with codes relating to throttle position or actuator performance, vehicle recovers after engine restart only to re-enter limp mode

What to check

With the engine off, inspect the intake throttle body (mounted on the intake manifold) for carbon buildup that could be jamming the flap. The actuator butterfly should move freely by hand when unplugged. Replacement units should be recalibrated using Ford IDS or equivalent software after fitting. If a workshop inspection is possible: Connect an OBD scanner and check for fault codes P0638 (throttle actuator control range/performance), P2100, or P2102.

Symptoms to notice

• Screen stays blank or frozen in reverse

What to check

Select reverse several times during the viewing and check the camera picture appears every time. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall REC-006401 or REC-006358 (reversing camera) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Symptoms to notice

• Clunking or knocking from the front suspension when traversing speed bumps, potholes, or during slow parking manoeuvres
• Wandering steering and vague on-centre feel, combined with uneven or accelerated tyre wear on the inner or outer edge

What to check

With the front wheels off the ground and supported at the chassis (not the control arm), grasp the tyre at 12 and 6 o'clock and attempt to rock it — any detectable play indicates ball joint wear. Check for worn ball joint boots (splits or missing lubricant will accelerate internal wear). Listen for clunking over low-speed bumps or during parking manoeuvres. If a workshop inspection is possible: A pre-purchase inspection should include a ball joint measurement using a dial indicator.

Symptoms to notice

• Usually no symptom at all
• Driver belt may feel loose or not lock on a sharp tug

What to check

1. 1.Ask the seller whether Ford has done the driver seat belt recall and ask for the dealer invoice.
2. 2.Pull the driver belt out fully, check it retracts smoothly, and give it a sharp tug to make sure it locks.
3. 3.Look at where the belt bolts to the floor and pillar for anything loose or twisted.
4. 4.If a workshop inspection is possible: a Ford dealer can check the VIN against recall REC-005639.

Symptoms to notice

• Soft or sinking brake pedal
• Brake fluid level low
• Wet patch on the inside of a front wheel

What to check

1. 1.Check the brake pedal is firm on the test drive and does not sink when held down.
2. 2.Look behind each front wheel with a phone torch for wetness.
3. 3.Check the brake fluid reservoir is at the full mark.
4. 4.Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2019/17536 (front brake hose) was done.
5. 5.A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Symptoms to notice

• Door will not latch or pops open
• Door ajar warning on while the door looks shut
• Door needs slamming to close

What to check

1. 1.Open and close every door several times with normal force: each should latch first time and the door ajar light should go out.
2. 2.Pull on each closed door from inside and outside.
3. 3.Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2018/17164 (door latch) was done.
4. 4.A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Symptoms to notice

• Rear seatback does not click firmly into place
• Seatback moves forward when pushed

What to check

Fold the rear seatback down and back up: it should click and lock firmly. Push hard on the top of the seatback from behind and from the front: it should not move. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2016/15625 (rear seat latch) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.