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 Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2005 Ford Explorer. The contact stated that shortly after refueling, the vehicle failed to accelerate with the accelerator pedal depressed. The contact stated that the vehicle then abruptly accelerated at a high rate of speed without the accelerator pedal being depressed. Also, the low oil pressure warning light and check transmission warning light was illuminated. The contact stated that they were close to home so they pulled into the driveway to check the oil level, which was low. The contact took the vehicle to a certified mechanic who diagnosed that the engine bearing needed to be repaired due to damage caused by a defective oil sensor not properly informing the contact when the oil level was low. The vehicle was not repaired. The contact contacted the dealer capital city Ford located at 8623 e. …
Tl* the contact owns a 2005 Ford Explorer. When attempting to start the vehicle, the engine began to sputter. She restarted the vehicle to resume normal vehicle operation. On another occasion while driving, the power steering and brakes failed without warning, which caused her to crash into a fence. The vehicle was taken to an independent mechanic for inspection on two separate occasions. The failure was contributed to the fuel sensor and throttle position sensor. The throttle position sensor was replaced. The repair did not remedy the failure. The failure mileage was 45,000. The current mileage was 80,000. The vehicle identification number was unavailable.
Filled tank to full (automatic shut off). When I started car the next time, gas gauge read empty and check engine light was on. I have had the malfunction of gauge before and has always come back after a few miles, but never light. After getting error light read, it is determined to be a faulty fuel sensor. This can be a safety hazard as there is no way for the vehicle to display the fuel correctly when the sensor malfunctions. I make sure not to overfill the tank as Ford warns that this could be an issue, which should have been fixed (not just that they know it can happen). Even by following the manufacturer's precautions, the part still failed.
We've replaced the fuel sensor in our 2005 Ford Explorer xlt twice in the past two years. We had 68,000 miles when we first replaced the fuel sensor. It is a costly fix. Now, August 2017, the fuel sensor is not working and our service engine soon light is on. This is a safety issue because we never know how much gas we have in the tank. The gas goes up and down and is not reliable. The computer never states the correct number of miles till emply. I'll be driving along and the gauge goes down to empty and the computer states -------.
Fuel gauge drops to empty after filling the tank up and starting it. The fuel gauge remains on empty. Service engine light comes on and stays on. It is unsafe not knowing how much fuel is in the tank because you could run out of gas at 70+MPH and cause a crash. Searching the issue online brought me to hundreds of 2002-05 Ford Explorer owners with the same exact problem. Ford motors should put out a recall for this issue because it is extremely dangerous.
Tl* the contact owns a 2005 Ford Explorer. While refueling the vehicle, fuel spewed out of the fuel tank as if it were full. The contact stated that fuel spilled onto his clothing and the vehicle. The failure recurred numerous times. The vehicle was taken to a dealer where it was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 98,000.
Driving down the road, suddenly the wrench light came on and the fail safe light came up. Vehicle would barely run. Cleaned throttle body and it seemed fine for a while. Then the same thing happened again, driving normal, then bam. This time it shut down and would barely stay running...just ordered a new throttle body. I will not own another Ford.
Fuel gauge is working intermittent. Tank is fill up with gas, but gas gauge show empty. Sometimes it comeback, after an hour or so and then, after 30 mins goes back to empty again. I read this is an issue on almost all Ford Explorer.
Cannot fill gas tank without nozzle or pump constantly shutting off. Have to bearly squeeze nozzle and trickle the gas in. Takes 10 times longer to fill tank than it should. Sounds like a very common problem with older fords.
I recently purchased a near new 2005 Ford Explorer. The vehicle is in pristine condition and has very low mileage to the point where it is below the industrial average. Since I purchased the vehicle, I have fueled it several times, always filling the tank to the top. Every time I have filled the vehicle up, the fuel gauge has dropped to empty and the mileage till empty indicator shows just dashes. In addition to the gauge dropping to empty my "service engine light" comes on immediately following the fuel gauge dropping. At first I thought it was possibly just a problem with my vehicle so I figured I'd have it fixed. Then out of curiosity I decided to check online and with other fellow owners of the 2002-2005 Ford Explorer model to see if they were having this problem as well. And to my surprise I found that it was a very common problem. …
Fuel System complaints in other Explorer years
Frequently asked questions
How common are fuel system problems on the 2005 Ford Explorer?
NHTSA has 66 complaints about the fuel & propulsion system of the 2005 Ford Explorer, 13% of the model year's 497 complaints. The component named most often is storage › fuel gauge system (5 mentions).
Is there a recall for 2005 Ford Explorer fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Ford Explorer. 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 Explorer fuel system problems start?
Half of the complaints with a recorded mileage happened before about 59,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires 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.