Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).
On 1/23 my wife (5 months pregnant) was driving alone with my 2 year old son through the ca desert on her way to phoenix, az. In our 2005 Ford Expedition with only 35K miles on it. About 20 miles from blythe, ca three fuel injectors failed. Luckily she found a Ford dealership in blythe that was open on that Friday and able to replace them. Upon arrival in phoenix, another dealer determined that the catalytic converter was destroyed as a result. I would like Ford to replace the remaining 5 fuel injectors before they fail. What kind of Ford policy is it to extend the warranty to 120K miles on a known defect and wait for disaster? It is insane to not be able to rely on our car for long distance travel and always worry about this incident repeating. The cost of replacing the catalytic converter and resulting pollution should also be a consideration to Ford? …
While driving the vehicle went into a heavy vibration from the motor and the smell of raw fuel was present. After turning off the vehicle it would not start. The vehicle was towed to the Ford dealer and the dealer stated that a fuel injector became stuck open. The injector filled the cylinder with fuel and caused the engine to blow up (severe damage). It was found that this occurred on Ford expeditions numerous times and Ford extended the warranty to 11 years, 120,000 miles and my scary experience occurred at 129,000. I previously replaced the motor at my own expense 2 years prior and Ford did not replace the injectors or notify me of an injector issue. Ford is stating that they will not honor the warranty and the engine damage was caused by the injector that was not replaced. It was found that Ford was aware of the injector issue since 2007. …
Tl* the contact owns a 2005 Ford Expedition. The contact stated that while driving at 65 MPH, the fuel cap and the tire sensor warning light illuminated. The vehicle was taken to the dealer (capital Ford of charlotte located at 5411 n tryon st, charlotte, nc 28213) where it was diagnosed that the tire sensor, the fuel cap and the windshield wiper blade needed to be replaced. The vehicle was repaired. The contact stated that the fuel cap warning light, failure occurred even after replacing the part. The manufacturer was not contacted and was not made aware of the failure. The approximate failure mileage was 94,368.
Fuel pump driver module failed due to design flaw which caused galvanic corrosion. Aluminum body of component acts as the sacrificial anode for the frame which is steel. This caused my vehicle to stall at 65mph and lose power and thus caused the loss of power steering and hydraulic brake booster while traveling a high rate of speed. This could be especially dangerous on highways, congested areas, or areas with pedestrians such as schools. I have also notified Ford of this problem.
I have a 2005 Ford Expedition, eddie bauer. Most recently (2 weeks ago), my check electronic throttle light came on, I called my local dealer and planned to take it in the next day. I work close to home and have limited driving distance. On the way home, the throttle went completely out and the vehicle cut off on the side of the road and was unable to be restarted and had to be towed. My local dealer did fix it in a timely manner. However...this is not the first problem. We bought it brand new and within a month the fuel injector went out when I was coming back home from out of town, my drivers side seat adjustment went out twice and had to be replaced. I am short and had to drive with my seat all the way back. 2 cam phasers had to be replaced back in the summer and then most recently this. I have 2 small children and would prefer a dependable vehicle. …
It takes 20 minutes to fill up my gas tank. Ford put some time of restriction or rerouted the fumes at the gas cap. I have to actually hold the nozzle back and inch from the opening and shoot the gas at the tank. This is a very dangerous situation and I am sure much more dangerous than the original problem the engineers were trying to correct (due to a lawsuit). Now Ford is saying that they will need to put the car on an engine analyzer ($160) then lower the gas tank ($500 to $600) in order to see if the fume vapor hose May be frozen or supposedly there is a replaceable filter that they located above the fuel tank. My response was ..."no engineer would locate a replaceable filter above the fuel tank"! …
I have a 2005 Expedition and it just cut off! I was driving about 40 miles per hour and it just cut off while I was pressing on the gas. I had to coast off the side of the road. I almost got in an accident! A warning alert said check electronic throttle and I could not move it and just stop and died. I waited about 5 minutes and tried to start my car again and it started. The engine light was on and took it to autozone and the diagnostic says that the throttle is stuck. This happened to me last year around about the same time and just went away. The year before I brought the car from the dealership and it did this to me 3 days after I bought it. I took it back to get it repaired and they fixed it no charge. Now they are trying to charge me. It cost 700 dollars everytime this part goes out. Why should I have to keep getting this repaired? …
2005 Ford Expedition [redacted] engine shuts down while traveling 50 MPH, failsafe mode indicator light comes on. This has happened twice in the last month. It is a huge life safety issue when you think you have control of the vehicle and you actually do not. I have 4 children I put into this vehicle and I fear our safety. I have been told today by Ford that the throttle body is faulty and needs to be replaced. This is a part that should never have to be replaced! Cleaned maybe but never replaced. I have 61, 000 miles on the vehicle and this part should not be bad. I will be replacing it this week, but I feel that Ford does not want to address this matter as I spoke to the service manager,[redacted]at al packer Ford west [phone] and also Ford corporate office at [phone] and all they said they would do is document the problem. …
This is the fourth incident regarding this vehicle. In each case, the car was traveling at a normal rate of speed under ordinary traffic conditions. Without warning, the car either lost power and shut off suddenly or lost the ability to accelerate and slowed to a stop. In each case the dashboard message center warning "check electronic throttle control" (or something similar) appeared. In each case the driver turned the ignition switch to the off position, waited several minutes, and then started the car. The warning message no longer appeared and the car ran fine without any further immediate incident. In this particular case (incident #4), the car was traveling at approximately 10 MPH and was turning right into a supermarket parking lot in Chevy chase, maryland. …
This is the fifth incident regarding this vehicle. In each case, the car was traveling at a normal rate of speed under ordinary traffic conditions. Without warning, the car either lost power and shut off suddenly or lost the ability to accelerate and slowed to a stop. In each case the dashboard message center warning "check electronic throttle control" (or something similar) appeared. In each case the driver turned the ignition switch to the off position, waited several minutes, and then started the car. The warning message no longer appeared and the car ran fine without any further immediate incident. In this particular case (incident #5), the car was traveling at approximately 25 MPH south on 14th st nw in washington, dc, when the car lost the ability to accelerate, and the "check electronic throttle control" warning appeared in the dashboard message center. …
Fuel System complaints in other Expedition years
Frequently asked questions
How common are fuel system problems on the 2005 Ford Expedition?
NHTSA has 65 complaints about the fuel & propulsion system of the 2005 Ford Expedition, 21% of the model year's 315 complaints. The component named most often is delivery › fuel pump (3 mentions).
Is there a recall for 2005 Ford Expedition fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Ford Expedition. 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 Expedition fuel system problems start?
Half of the complaints with a recorded mileage happened before about 74,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.