Question about 2002 Ford Ranger Regular Cab

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Rotted Engine Block

I own a 2002 Ranger 4 cylinder with only 62,000 miles on it. After replacing the thermostat housing unit and having issues with a radiator leak that would not stop my mechanic noticed a very small hole behind the water jacket which after running his hand in the area he discovered the leak became the size of his finger. A hole rotted through the block behind the thermostat.
Please tell me how a truck with only 62,000 miles on it which is faithfully maintained can have a rotted block.
Personally I think this is a Ford problem and not mine. I am in search of other unhappy ranger owners that had a similar problem. Seems like I can't have the only bad apple in the basket!

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  • Ranger 2002 May 29, 2008

    The mechanic didn't over tighten the bolts. This is definately a Ford issue. The block is literally rotted behind the water jacket.

  • Ranger 2002 Jun 12, 2008

    We trailered our ranger to a ford dealer. Upon inspection from a certified Ford Mechanic it was determined that "yes" we were correct. Our block was in fact "rotted". Ford chooses to do nothing about it. No Good Will Assistance--NOTHING- but leave us holding the bag on this one.

    Nothing was over-tightened.This is a defective engine block.

    I have requested paper work from the attorney general's office in order to file a complaint against Ford Motor Co.

    After spending much time on the computer I have also found documentation of other Ford Rangers w/2.3 with the same exact problem right around the same mileage so this is in fact a Ford issue!!!

    ALL Ford Ranger owners around the 2002 year--BUYER BEWARE!

  • bobbondo Oct 29, 2008

    i had the exact same problem on my 2002 4cyl ranger in the same spot of the block. Mine gave out 38 months after i bought it brand new with only 23,000 miles on it . I was past the 36 month warr and they said too bad!

    I bithched and moaned for a few days and they agreed to fix it for $800

    the put a rebuilt top half on it. when i left the deale the check engine light came on. they said it was unrelated some sort of sensor and charged me $300 to fix that. now some pipe that goes to the heater is rotted and will cost $1000 to fix , i've got 43,000 on this lemon. what recourse do we have?

  • eyedontget1t Nov 19, 2008

    I also have a 2002 Ford Ranger 4 cyl. 2.3 liter. Back in 2005 it overheated and had to be towed to the dealer. Dealer told me that because of the newer style of thermostat Ford put on the vehicle (I now think they were referring to the thermostat housing), electrolysis had occurred and rotted out the block. The truck was still under warranty so they did a "short block" replacement and put in a block with zinc rods in it that would counteract the electrolysis. This is what I was told anyway. Truck still acted a little funky - the temperature gauge would spike intermittently getting on a highway forcing me to slow down until the gauge went down and then it would be ok. That hasn't happened for quite a while. But today I noticed that I have no heat, leading me to believe that the thermostat is stuck open. I hope it's not happening all over again but I wanted to chime in on an issue that is clearly Ford's fault. Back when it happened to me I found absolutely nothing on the web about it.

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  • Ford Master
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Well knowing engine blocks this sounds like an inperfection in the block when i came out of the molding process of the manuafacture these blocks should be able to take a quite a bit
like an air bubble or piece of **** metal in the block from manuacfacture this you should really bring to dealers attention they should uphold the hundred thousand mile warranty on the mecanicalbility of engine if they dont i would go to attorney general and ask for advice seeing that this is a manufactures problem
the other is over tightening of bolts in which cracked the block

Posted on May 29, 2008

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Fig. Exploded view of the thermostat housing (1), thermostat (2) and outlet pipe (3)



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