Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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 that while driving and making a turn at various speeds, there was an abnormal popping noise detected. There were no warning lights illuminated. The contact stated that the spark plugs, cam shaft sensor, and coils were replaced. The vehicle was taken to the local dealer where it was diagnosed that the CV axle boots were torn. The vehicle was repaired but the failure persisted. The manufacturer was contacted and the contact was referred to the NHTSA hotline. The approximate failure mileage 91,082.
The undercarriage and frame is rusted .Ford said it was not under warranty and the truck was unsafe to drive. Most of the rust is mainly at the rear of truck and if the truck was hit in the rear it would be very unsafe to drive.
This is the 2nd Ford F 150 pick up with which I've had rusted frames! The 1st, a 1999, I ended up junking. This one needs $2000 of welding to make the frame safe to drive. The proprietor of [redacted] Welding says he's done over 40 F 150's for the same problem with the frames. My mechanic, [redacted], at Shaw's Automotive, says he's seen F 150's that have collapsed around a lift when they were in for a simple oil change. The internet states this is a common issue with F 150's. SAFETY, SAFETY, SAFETY! These trucks should not be on the road until Ford repairs them or buys them back, like Toyota did in the 90's!!!!
Frame on passenger and drive side by transmission, fuel tank, and rear leaf springs are rusted and have no integrity left. No structure integrity if in an accident. If fractures completely, will loose control of vehicle as the bed will contact cab, driveshaft will jamb into transmission, lock up brakes from pinched brake lines, loss of brakes from severed brake lines, lose control and go into on coming traffic or into roadside structures including pedestrians. NOTE: Your system will not let me upload pictures.
The main frame is so corroded that it is unsafe to drive. The body has no rust and the engine only has 73,000 miles on it. I went to the Ford garage for new tires and they found the damage to the frame
Yes a drunk driver ran into me and I think the officer let him just call his wife to come get him cause he was to drunk to drive and it was maybe involving him doing on repairs to the officers car the reason he got off scot free, I May could understand it but he like broad sided me and sent me flying across the seat and I saw him take off and so I was reaching around the steering wheel to try and make a sharper turn and give it some more gas evidently it did not work cause this was June 2 of 2018 and my shoulder is still hurt,he has insurance I have insurance but after the emergency room visit I have not been able to hire a lawyer,I have not even been able to get a doctor to tell me what's wrong with my shoulder,I can't get into an ortho group cause they say we don't take third party checks ,I finally got into the regional one in memphis and made the appointment 4 months ago,and still …
I have a 2005 f150 fx4 that I bought in 2010. In 2017 with the truck being 12 years old. I had to remove the vehicle from the road because of frame rot! This was my baby and taken well care of. Both sides in front of the rear axle are rotted out to the point a jack just goes right through them. The inspection failed because if they would have lifted it, it would have folded in half. Also has a broken front left coil spring. I should have a vehicle worth around 8-10 grand that is going to sell for scrap metal priced. Why are American auto maker not held responsible for making defective vehicles? My previous vehicle was an 199o Toyota tacoma that had a frame rot recall and mine was spotless. Fast forward, bought an American made vehicle that cost me 15 grand and got 6 and a half years out of and no one holding Ford responsible! Sickening!
I just wanted to add my vehicle to the list of complaints about the differential. Mine makes noise and has made noise for quite some time. I thought it might be the tires or rotors. I found out that it was coming directly from the rear differential. Based on the complaints I have heard, I am pretty sure this is the same thing. The noise sounds like metal running on metal. I believe this should be something Ford should pay to fix. If I have to pay for it, I'm definitely not using Ford. I read that's many people have the same complaints. This failure is security public problems, because accidental or crash May occur.
The lower ujoint on the steering column is freezing up from corrosion. In the past I had noticed it was getting harder to steer so I would spray the joints with penetrating oil and they would improve. Today the joints were so bad it was as if the power steering had given out, to the point I pulled over to check that I didn't blow a power steering hose. I will not let my wife drive this truck until the part is replaced but at a cost of $200 for the part it will have to be parked for a while. I understand normal wear but this is common enough to draw some attention I hope.
Tl* the contact owns a 2005 Ford f-150. After replacing the tires on the vehicle, the contact heard a cracking noise when the vehicle was placed on a lift. The independent mechanic confirmed the frame was rusted through to the point that it was unsafe to place on the lift. The vehicle was taken back to frederick motor company (1 waverley dr, frederick, md 21702, [phone]). The contact was informed that they could not assist since the vehicle was not included in a recall. The manufacturer was not contacted. The failure mileage was 57,000.
Suspension complaints in other F-150 years
Frequently asked questions
How common are suspension problems on the 2005 Ford F-150?
NHTSA has 49 complaints about the suspension of the 2005 Ford F-150, 4% of the model year's 1,112 complaints. The component named most often is front (6 mentions).
Is there a recall for 2005 Ford F-150 suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 57,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 1 injury to suspension 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.