Ford Ranger: Rear Leaf Spring Main Leaf Cracking and Separation

The PX-series Ranger rear leaf spring packs are prone to developing cracks in the main leaf, typically at the highest stress concentration points near the U-bolt clamp pad or at the spring eye. Fracture can occur progressively due to metal fatigue from repeated heavy loads or towing at or near GVM, but has also been observed on lightly used vehicles. A separated main leaf can punch through the floor, contact the tyre, or cause sudden and violent loss of rear suspension control at highway speed, representing a serious safety risk.

• Rear of vehicle sitting noticeably lower on one side than the other
• Audible clunk or crack sound from the rear on rough roads or speed bumps
• Visibly cracked or offset leaf visible on inspection
• Tyre rubbing against a broken spring fragment
• Sudden change in handling stability during highway cornering

1. 1

   With the vehicle on flat ground, walk around and visually inspect each leaf spring pack from the side and below.

2. 2

   Look for cracks, fractures, or any leaf sitting at an odd angle relative to the pack.

3. 3

   Check for corrosion or rust starting at the edges of the spring leaves which can accelerate cracking.

4. 4

   Note whether the vehicle sits level at the rear — a sagging side may indicate a spring has already cracked or lost a leaf.

5. 5

   Ask if the vehicle has been used to tow at or near maximum capacity.

Parts involved: Rear leaf spring.

$900 to $2,800 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Has the vehicle been used for regular towing, and at what loads?”
• “Have the rear leaf springs ever been inspected, replaced, or any recall work carried out?”
• “Has the vehicle been fitted with a lift kit or aftermarket springs that may have increased stress on the factory components?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.