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-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Vehicle had just returned home after being driven a considerable distance. Vehicle shut off for a few minutes when fire started under the hood and moved into cab. Insurance company hired a fire origin and cause analyst and it was determined that fire was caused when fuel leaked from the banjo fitting on the fuel filter onto the hot surface of the engine. The banjo fitting on the lower portion of the fuel filter was covered with a heavy layer of fuel varnish. The bolt in the banjo fitting was checked and found to be extremely loose. This occurred on 6.0l diesel engine. There looks to have been similar problem on gasoline engines which had a recall date of 6/7/05 and NHTSA id number of 05V266000. Would like to know if Ford has seen problem on diesel engines?
Tl contact owns a 2005 Ford f-350 SD. When attempting to start the vehicle, it would not start. While driving at various speeds, the contact noticed white smoke. She took the vehicle to the dealer on numerous occasions, but they could not determine the cause of the failures. The VIN was excluded from NHTSA campaign id number 05V270000 (electrical system:wiring); therefore, she would have to replace the fuel injection control module at the cost of $1,133.52. The vehicle was repaired. The failure mileage was 69,000 and current mileage was 119,000.
For the past week my truck has been taking longer to start then normal today it started to stall on my I was able to get it home while it stalled 4 more times on the way. Shopped at a friends shop on the way home and had them scan the computer found out my ficm is no go my ipr is bad and my stc fitting is bad they found the stc when they pulled the turbo aswell as my dummy plugs.
I have a 2005 Ford f-350 with approximately 50,000 miles on it. Over the past 4 months my truck has been not starting after it has been driven and occasionally stalling while being driven. I have had the cam sensor, crank sensor, & fuel sending unit all replaced to no avail. I brought it to the Ford dealer and they were unable to "reproduce the not starting", told me to change all filters to Ford brand and change the oil. After spending $350 on just filters the truck is still broken, I can not drive it. There is a campaign for this problem #05V270000, unfortunately Ford says they can not fix my vehicle because my VIN# was not included. I had a friend look at my truck who has a computer to look up the codes, while the truck is plugged in. He reproduced the not starting while the computer was plugged in and the code came up for the ficm which is what the recall from NHTSA is for. …
I am uncomfortable with the dependability and safety of this 2005 Ford f350 6.0 diesel truck. The high pressure oil lines, valves, pump, coupler and injector ends where the high pressure oil connect are failing in a large number of these 6.0 diesel engines. Mine has had the valve and coupler replaced in seperate events. Both repairs cost over $1000.00. Ford needs to be forced into designing a fix for these oil systems and recall them them. When any component of this high pressure oil system fail the engine quits running and the driver and occupents are sitting ducks. I wonder how many injuries or deaths have been related to these failures. No one should pay in excess of $40.000.00 for a truck and have to spend thousands ot dollars in repairs just after 100,000 miles and still have to worry about when and where the next failure will happen. …
I own a 2005 f350 4x4 crew cab power stroke diesel truck. I had the truck in for some warranty work just before it reached over 100.00 miles. I had to have injectors replaced. I later found out that the fuel tank was delaminating. Silver particle and rust is getting into the injecters and clogging filters. I been told that Ford is not covering this problem at all. The truck now has 109,000 miles and I no longer have a warranty on the injector. They never told me till after the warranty was up that the fuel tanks where failing. Now from what I can tell everyone is having problems with there fuel tanks. Ford has claimed that it is the caused from bio-fuels but I have never put a drop of bio-fuel in my truck before. I also been told that if you buy a new tank it will have the same problem. My truck will not run all the time and dies on me often. …
Fuel tank lining is peeling off causing failure to injectors/ pump and filters. Causes power loss in traffic which is unsafe. This has happened to me three times since August 2010 in interstate traffic. Ford claims bio-diesel is to blame, bio-diesel makers blame Ford. Personally this has cost me $2600 since aug 2010. (replaced filters twice and 5 fuel injectors) truck is not running at this time due to the same problem. Estimated cost to repair $1200 minimum if injectors are okay. This is a problem that Ford is well aware of and should be sending notices to affected customers. Owners of these trucks have no way of knowing what percentage of bio-diesel or if any bio-diesel is in the fuel since it is not marked on the pumps. Fords solution is for the owner to buy a new fuel tank that is compatible with 5% bio-diesel.
The inter liner of the fuel tank disintegrated causing the fuel to contaminate the fuel injectors and the fuel pump. The local Ford dealer recommended that the fuel tank, the fuel pump and all the fuel injectors be replaced. Total cost between $5000 and $6000 dollars. Gave the approval on May 3rd 2011. As of July 5th still waiting on the new fuel tank. Ford has had so many of these fuel tanks fail that there is a national waiting list for the replacement tanks. Adding insult to injury, this is a work truck. Everyday it's unavailable cost the company $100.00 to $150.00 a day. Add that into the repair and now it's costing us 10K to 12K. At this time, we still have no answer from our Ford dealer as to when we can expect the new tank. At the very least, I think Ford should be responsible for the repair.
Tl contact owns a 2005 Ford 350 super duty. While driving approximately 65 MPH, the vehicle suddenly decelerated and stalled. The contact was able to pull over to the side of the road and restart the vehicle. The vehicle was taken to the dealer where the technicians replaced the fuel module. After the repairs were made, the vehicle stalled a second time. The vehicle was towed to the dealer where the technicians stated the fuel injector needed to be replaced. The vehicle was not repaired. The VIN was unavailable. The manufacturer was contacted and stated there was a recall 05V266000 (fuel system, gasoline: delivery: hoses, lines/piping, and fittings) but the VIN was not included. The approximate failure mileage was 107,000.
Coming home from a camping trip with a 5th wheel camper & truck just stopped working. Come to find out the stc fitting on high pressure oil pump shot apart & cracked rear timing cover. After being stuck on the highway for over 8 hours, stranded at the campground for 4 more days & $3000 to get it fixed, we then finding out that this is a common problem with this engine. This stc fitting has since been changed by the manufacturer so that it is one piece now, however there has not been a recall on it. We have several Ford vehicles and it is very upsetting to go through all of this when a simple recall could have avoided it. Thank you for your attention to resolving this matter & helping us get a refund for the $3000.
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-350 SD years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-350 SD?
NHTSA has 29 complaints about the fuel & propulsion system of the 2005 Ford F-350 SD, 13% of the model year's 217 complaints. The component named most often is delivery › hoses, lines/piping, and fittings (1 mentions).
Is there a recall for 2005 Ford F-350 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-350 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 73,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 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.