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 F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2005 Ford F-150. The contact stated while driving at an undisclosed speed, he smelled an abnormal fuel odor. Additionally, the contact stated that while the accelerator pedal was depressed, the vehicle failed to accelerate as needed. The check engine warning light was illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 200,000.
Pulled out of driveway and made it 50 feet and whole truck shut down right on the road. Could not make the vehical restart no click or anything dead right where it stopped. Could of caused an accident. Had to have truck taken to a shop they took a week to find out that the electrical fuel system harness had a dead short in it. So no fuel going to the feul injectors or to the key to start the vehical. Still have head lights and breaks and radio. Just no way to restart the vehical. They checked thw wires and after unplugging many wires to the fuel system and retesting it started. Left with the truck a day later the same thing happen but this time i had to jump a curb to avoid an accident and coasted into a parking lot. I got out and wiggled a few of the wires and the truck started back up. …
Tl* the contact owns a 2005 Ford f-150. While driving various speeds, the vehicle lost power and misfired, and smoke could be seen coming from the rear of the vehicle. The vehicle was taken to an independent mechanic who initially diagnosed a fuel leak from the exhaust. Upon further investigation, the mechanic stated that injector number 7 was not closing correctly and causing the fuel to enter the cylinder. As a result, the motor needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The dealer stated that the VIN was excluded from a recall on the injectors. The recall details were not provided. The failure mileage was approximately 76,000.
My wife was at a complete stop at a red light in the left turn lane. She is driving a Ford f150 truck, with less than 6,000 miles. While waiting at the light, the engine began accelerating unexpectedly. She had her foot on the brake and this initially held the vehicle in place. The acceleration continued to increase and she pressed harder on the brake petal, in an effort to keep the vehicle from moving forward. The vehicle's acceleration increased and the vehicle lurched forward, striking the stopped vehicle in front of her. No one was hurt and I had the vehicle towed to the Ford dealership. The service tech at the dealership, told me that it could be a number of problems with the fuel injection system. It should be noted that the day before, I was driving the truck and while stopped at a red light, I thought I heard the engine running in a loud or rough manner. …
Tl contact owns a 2005 Ford f-150. While driving approximately 35 MPH on normal road conditions, the bed and cab compartments of the vehicle burst into flames. The contact was notified by another motorist. He immediately turned off the engine and exited the vehicle. He noticed fuel leaking from the vehicle onto the roadway, which also caught fire. The vehicle became engulfed in flames and was destroyed. There were no warnings prior to the fire. The fire and police departments were called to the scene and a report was filed. The fire department stated that the fire originated on the top surface of the fuel tank. There were no personal injuries or property damage. The vehicle was towed to a collision center. The manufacturer was notified of the malfunction and the insurance company has not determined the cause of the failure. The failure and current mileages were 47,000.
Known issue with fuel injectors caused premature engine failure at 45K mi. Too much fuel when compressed and ignited blew the piston apart. Ford replaced engine. 80K miles later similar problems and recommendation is another engine. Two 5.4l engines with less than 130K overall miles is absolutely unacceptable. Web searches say there is current litigation in progress over these 5.4l engines. I'm making a formal complaint that the basis of the lawsuit has merit. Ford has already settled a suit over the spark plugs for these 5.4l but the problems with these engines goes much deeper. I'm thankful my engine failures happened without any additional incident.
Tl* the contact owns a 2005 Ford f-150. While driving, the vehicle idled without warning. The contact had to pull the vehicle over to restart it, but it continued to idle. The maintenance warning indicator illuminated. The vehicle was taken to an independent mechanic who diagnosed that the fuel injection control module needed to be replaced. The vehicle was repaired, but the failure recurred. The dealer was not notified. The contact referenced NHTSA campaign number: 05V270000 (electrical system). The manufacturer was notified of the failure and stated that there was no recall associated with the VIN. The approximate failure mileage was 98,778.
Have owned this truck bought new, 2005. Have used sparingly only 15K + miles. Over the years I have experianced a number of occasions when it tried to accellerate when I went to brake. First thought it a quirk or floor mats. Recently nearly trashed a parked car while backing ito a parking space. Continued to accellerate dispite standing on brake. There is no longer any doubt that this is a problem with sua, sudden unintended accelleration, that Ford has never admitted. I have made sure I am off the gas pedal and the floor mat has been removed. This happens when the vehicle is moving and when trying to brake!
Vehicle stalls and or surges and has dead spots. After many attempts to solve the issue it still persists. Looking on line it is a common problem with this vehicle.2005 -2008 f 150 5.4. It is especially dangerous when towing a trailer my wife has almost got into accidents a couple of times while towing a horse trailer and is now afraid to drive the truck. Spoke to Ford but no real response. I think this issue needs to be looked at further especially when considering people do tow with their trucks and it amplifies this issue. Thanks mario .
Tl contact owns a 2005 Ford f-150. The contact noticed white smoke coming from the exhaust. The vehicle was towed to the dealer and they stated that the fuel injectors failed, thus causing the engine to fail. The cost to replace the component would be approximately $7,300. The manufacturer stated that there was an initiative that would extend the warranty on the fuel injectors. The contact is waiting on a decision on whether the manufacturer will assume financial responsibility. The failure and current mileages were 73,000.
Fuel System complaints in other F-150 years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-150?
NHTSA has 82 complaints about the fuel & propulsion system of the 2005 Ford F-150, 7% of the model year's 1,112 complaints. The component named most often is fuel injection system › injectors (7 mentions).
Is there a recall for 2005 Ford F-150 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Ford F-150, though it has 3 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 F-150 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 3 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.