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-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2005 Ford f-250 SD. The contact stated that while driving approximately 55 MPH, the vehicle stalled without warning. The vehicle failed to restart and was towed to an independent mechanic for diagnostic testing on two separate occasions. The mechanic was unable to locate a failure on each visit. The vehicle was also taken to the dealer who discovered that the failure was contributed to the faulty fuel injection control module and fuel pump. The vehicle was repaired. There was a recall under NHTSA campaign number: 05V270000 (electrical system) however, the VIN was not included. The manufacturer was notified of the issue. The approximate failure mileage was 138,576. Ma 08/10/15 updated 11/30/2015
I have a 2005 f250 diesel truck. I was driving on I-95 when I noticed flames coming from behind my cab. I quickly pulled off to the shoulder and tried to extinguish the fire but it was to late. The fire burned the truck completely.
[redacted]2005 Ford f 250 super duty there has been a recall NHTSA recall campaign number: 05V270000 regarding wiring harness according to Ford my truck does not meet the recall criteria it misses VIN spectrum by a few units and is built in one of the factories involved in the recall (kentucky) however the symptoms: no pick up upon acceleration engine missing out hard starts occasionally . Ft lauderdale maroone Ford indicates that the ficm/icm/icp module May be bad and it will cost $1800.00 to replace and they are not sure it will resolve the issue as the other results of diagnosis required replacing camshaft sensor positioning switch the injectors have been replaced under recall this all started @ aprox 50,000 mi currently @86,000 mi have contacted Ford customer service they say go to dealer and HEV truck run through diagnostics again at a cost of $150.00 to see what out come is still …
This event had no warnings leading up to the failure. This failure occurred once and was debilitating. My 2005 Ford f250 (6.0 diesel) suffered a leak in two orings and a crack in an oil line in the high pressure oil system. The result was a vehicle that died and would not start. This vehicle only has 40,000 original miles on it. Online research has revealed that this is a design flaw in the 2004 & 2005 model years. Ford has issued TSB's on the problem however never notified consumers of the defect to forewarn or correct the affected model years. The engine has sensors that shut the engine down and prevent it from starting when oil pressure is lost from such defects. My vehicle was towed to Ford, however the warranty had expired in December 2009. I have tried to resolve cost issue with Ford to no avail. …
2005 Ford f250 super duty / crew cab, 6.0 l diesel / 61,264 miles. Lack of performance(18mos), intermittent engine stumbling(6mos), intermittent white smoke during start-up, hard to start during cold temps(12mos), black smoke during poor performance and stumbling(2mos) and failure to start. Engine diagnostics codes: p0261/264/267/270/273/276/279/282 and p0611. Towed vehicle to dealer for diagnostics and repair. Dealer found same diagnostics and replaced fuel injector control module (ficm). Ficm needed for $140 core charge. Warranty 5yr/100K miles 6mos out of date but under mileage - extended warranty found to be concurrent with manufactures. Ford motor co. Has left decision to complete as warranty repair or defer portion of cost to dealer.
Oct. 20, 2009, truck died while pulling 5th wheel up steep mtn. Road to kennedy meadows, ca. Bad situation. After 3 weeks in Ford garage, in ridgecrest, ca. Several parts replaced all related to the high pressure oil system used to fire injectors on this 6.0 powerstroke engine. Jan 26, 2010. After pulling the 5th wheel for about 100 miles through heavy traffic and parking trailer in my driveway, I came back later and truck wouldn't start. Towed to lake elsinore Ford and they replace the oil pressure regulator. This is all over the powerstroke sites on the net. My nephew has had the same problems. Ford knows this too. Both of these incidents could have resulted in wrecks, there is no warning, the engine just dies.
Tl contact owns a 2005 Ford f-250 superduty. Sporadically, the vehicle experiences a no start condition. On one occasion, while driving 25 MPH, the vehicle stalled without warning. The vehicle was towed to a dealer and they stated that the fuel pump, tank, and injectors needed to be replaced at the cost of $4,000 due to corrosion. The technician added that they received numerous complaints and failures with this particular make and model vehicle. The manufacturer stated that they would not assume any responsibility for the repairs and referred the contact back to the dealer. The vehicle has not been repaired. The failure and current mileages were 23,000. Updated 04-17-09 upated 04/20/09.
Tl* the contact owns a 2005 Ford f-250 super duty. The contact stated that whenever the air conditioner was operated, he could smell exhaust fumes in the interior of the vehicle. The failure would persist whether driving or sitting idle. When sitting idle, the smell was overwhelming. The contact also stated that when defrosting the windows in cold weather, the fumes would cause the windows to fog excessively. The dealer advised they were aware of the failure however; the contact would be responsible for any repairs. The vehicle was not serviced. The failure mileage was 60,000 and the current mileage was 124,702. Updated 12/01/10. Updated 12/07/10
This 2005 Ford f250sd I bought 3 years ago has been nothing but trouble. In the first 2 months of owning the vehicle the oil sensor switch went bad leaving me stranded twice. I finally talked Ford into replacing the switch since it had only been 2 months from purchase. Then a year later the fuel control module this site says it is a recall for this year but Ford says it is not. Cost $1200 now again not even 3 years later the oil switch blew out again. Even though a trained Ford mechanic replaced it. It is costing $1500 to have replaced. With all the same complaints with this motor it is a wonder why Ford has not made a recall.
My f250 super duty truck stalls while driving, specially after turning corner. All 3 times the complete fuel injector assembly was replaced , 5/15/07, 12/15/07 & 8/15/07. Had fuel tank cleaned and found rust remains in bottom of fuel tank. The computer and wire harness had to be replaced 12/15/07. Fuel tank rusts from inside and blocks fuel line from fuel tank and water separator and consequently starves injectors from fuel which is why they burn up. See www.forddoctorsdts.com/articles/article-07-07.php. Each time I bring in the truck it costs for a truck with between $1,000-$4,000 with only 110,000 miles on the truck.
Related recalls
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
On certain pickup trucks and chassis cab vehicles equipped with 5.4l or 6.8l gasoline engines, the fuel jumper line May have an incorrect end form.
Remedy: Dealers will install an external retention clip at the fuel jumper line to the main fuel bundle connection. The recall began on June 20, 2005. Owners May contact Ford at 1-800-392-3673.
Fuel System complaints in other F-250 SD years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-250 SD?
NHTSA has 26 complaints about the fuel & propulsion system of the 2005 Ford F-250 SD, 9% of the model year's 295 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 2005 Ford F-250 SD fuel system problems?
Yes — NHTSA recall 05V-266 (hoses, lines/piping, and fittings, Jun 9, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2005 Ford F-250 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 60,000 miles, and 20% 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.