Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Ford E-350 owners, lightly cleaned up (personal details are redacted by NHTSA).
The agency for community transit provides services for madison county mass transit district who is responsible for public transportation services in the madison county, illinois and metropolitan st. Louis, mo. Area. We have approximately 48 Ford e450 van cutaway chassis equipped with turtle top bus bodies, all equipped with 6.0l diesel engines. Buses are 2004 & 2005 model years. Coking (un-combustion) deposits form on the EGR valve causing drivability issues such as lack of power, surges, and stalling. This condition is especially dangerous when the bus develops this condition when crossing intersections, railroad tracks etc and is transporting passengers both mobile and handicapped. Drivers have voiced their concern over this condition as they believe it is unsafe for them and their passengers. Ford motor company has replaced EGR valves (approx. …
This bus is owned by first baptist church of grant, al. About one year ago we started having times when the bus would crank but not start. Our mechanic has checked it four different tlimes, however, every time except this time (5th time) it started when he went to check it. This time we were taking our seniors on a trip, but when we went to crank it, it cranked but would not start. We had it towed to woody anderson Ford in huntsville, al. I spoke with the truck service manager today and he told me the engine wiring harness was bad. This bus only has 30,000 miles on it. It has been at woody anderson Ford 4 days. I know recalls are based on the VIN number primarily. This is a like new bus and already had to replace the fuel injectors, turbo charger, and a couple of different sensors. Anyone with any common sense knows that it is not normal for an engine wiring harness to go bad. …
While drive on highway,vehicle began to lose power when I encountered a hill. It bogged down and struggled to make it to top of hill and lost speed down to 30 MPH or less and then died. It would not start right away, but after letting it sit for 15 minutes, it started and had regained power and I drove it till I got to the nest hill and did the same thing several times till I made it home 3 hours later for a 10 mile trip. I checked online on the vehicle for Ford owners forum and saw that several people encountered this problem before and described it as bogging down and losing power. Some one suggested changing the EGR valve which I had done, and the fuel filters as well as air filter. When I removed the bottom fuel filter under the van, I captured the fuel in the filter and line and it had what looked like silver paint. I kept the sample and it is soft and pliable. …
Tl* the contact owns a 2005 Ford e-350 diesel. While driving approximately 35 MPH and exiting the highway, the vehicle stalled without warning. The contact was able to maneuver the vehicle as it coasted off the ramp and onto a second highway where the vehicle was maneuvered to the shoulder. The contact was able to restart the vehicle yet it continued to stall repeatedly. The vehicle was towed to a local mechanic where the contact was advised that the injection pump and injection control sensor was defective and would need to be replaced. In addition, the mechanic advised that the high pressure oil pump was damaged and the housing which would also need replacing. The vehicle was repaired. The manufacturer was contacted and advised that the vehicle was not included in any recalls. The failure mileage was 67,294 and the current mileage was 67,310.
Driving uphill on I-70 eastbound by silverthorne, co the engine simply quit. Limped to side of highway and tried to restart - nothing. Batteries are new, etc just no turning over of the engine. Thoughts are a bad ficm, which there is supposedly a recall but Ford denied that when I called this morning. Had the vehicle towed to a shop in arvada, co for diagnosis and repairs. Sounds like the EGR system is about to go, the ficm is shot and wiring harness for computer is gone - all things Ford is aware of but adamantly refuses to do anything about. This leaves the consumer in the position to have to spend thousands of $'s to repair their design flaws.
Tl* the contact owns a 2005 Ford e350 super duty. The contact stated that he would have to wait hours for the engine to cool down before the vehicle could be started. The vehicle was taken to a dealer for diagnosis and the contact was informed that the engine oil cooler, injectors and the EGR cooler would all need to be replaced. The vehicle was taken to an independent mechanic and was repaired. The manufacturer was notified but offered no assistance. The failure and current mileage was 79,000. Updated 1/7/13 the consumer stated the dealer rebuilt the engine, possibly due to deterioration of the fuel tank liner. Updated 01/09/13
Tl contact owns a 2005 Ford econoline e350. While driving 60 MPH, the vehicle shut off completely and lost power steering ability. The Ford dealer and manufacturer offered no assistance. The vehicle was towed and it was discovered that the interior of the fuel tank had delaminated and caused the engine to lose power. The dealer would not repair the vehicle under the three year, 36,000 mile warranty or under a recall. The contact was not informed if his vehicle was included in any recalls. The failure and current mileages were 35,000.
Tl* the contact owns a 2005 Ford e-350. The contact was driving 40 MPH when the vehicle stalled without warning. The vehicle was towed to the contact's residence where it was inspected by an authorized mechanic. The mechanic advised the contact that the filter at the bottom of the engine had become clogged and needed to be replaced. The vehicle was repaired but the failure recurred. The manufacturer was notified of the failure. The failure mileage was 158,000.
2005 Ford e-350 ambulance was driving with lights and sirens to a 911 call when the engine died. The crew was barely able to control the vehicle to a stop. This has happened 2 times before, both times the vehicle was sent to a Ford dealership service center and they have been unable to find a solution to the problem. They are unwilling to replace the engine and all drivetrain systems.
Tl* the contact owns a 2005 Ford e-350. While driving 40 MPH, the engine stalled without warning. The contact was able to restart the vehicle after repeated attempts. The failure occurred multiple times. The vehicle was not diagnosed or repaired. The manufacturer was notified. The approximate failure mileage was 45,000.
Engine complaints in other E-350 years
Frequently asked questions
How common are engine problems on the 2005 Ford E-350?
NHTSA has 21 complaints about the engine & cooling of the 2005 Ford E-350, 38% of the model year's 55 complaints. The component named most often is engine › diesel (11 mentions).
Is there a recall for 2005 Ford E-350 engine problems?
No. NHTSA lists no engine & cooling recall for the 2005 Ford E-350, though it has 12 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Ford E-350 engine problems start?
Half of the complaints with a recorded mileage happened before about 30,000 miles, and 27% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.