Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Ford F-350 owners, lightly cleaned up (personal details are redacted by NHTSA).
[redacted] approx age 40 lives and works at [redacted].[redacted] can also control the computers to cancel out and delete the use of catalytic converters, delete the use of DEF intake, delete the use of DPF particulate filters, and not react to controls such as manual braking or acceleration because the computer is controlling when and not the driver. [redacted] strictly states that he cannot have any emissions controls such as EGR, DEF, DPF, catalyst, or any pollutant controls. [redacted] intentionally set it up to have flaws and be dangerous for one reason: to get the customer to keep returning again and again with vehicle problems, wiring electrical problems, performance problems, overheating problems, and never ending engine problems not to mention transmission problems because the transmission could not handle the increased output of the engine. …
Tl* the contact owns a 2005 Ford f-350. While driving 45 MPH, the vehicle wobbled. The steering veered to the left when the wheel was turned to the right and vice versa. The vehicle was taken to an independent mechanic who diagnosed that the front tie rods, front stabilizer bars, gear box, and multiple parts on the front of the vehicle needed to be replaced. The vehicle was repaired. In addition, while driving 65 MPH, the vehicle lost power. The vehicle was towed to an independent mechanic who diagnosed that the injectors, cam shaft sensor, and the wiring harness for the injectors needed to be replaced. The vehicle was repaired; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 102,000.
I have a 2005 Ford f350 diesel powerstroke that has the fuel tank lining falling off and its gotten to my fuel lines and fuel pump causing the truck to come to a complete stop while I was driving down the freeway hauling a 12ft trailer with a 10000 lbs tractor on it. I had to get it towed to a shop where they replaced the fuel pump and filters. One month later it did the same thing while on the highway again it just died the mechanic says my fuel tank is the problem the lining inside the fuel tank is chipping away and it has gotten to the fuel system again this is a frequent problem with Ford diesel tanks and they wont take responsibility. This second time around I am having to replace fuel injectors and the filters again.
Tl* the contact owns a 2005 Ford f-350. While driving 65 MPH, the vehicle stalled and the check engine warning indicator illuminated. The contact coasted the vehicle to the side of the road and powered off the engine. The vehicle was restarted and was able to drive normally. Later, the vehicle stalled and failed to restart. The vehicle was taken to an independent mechanic where it was diagnosed, but a failure code could not be found. The vehicle was not taken to a dealer and was not repaired. The manufacturer was notified of the failure and informed the contact that the VIN was not included in a recall. The approximate failure mileage was 130,000.
Tl* the contact owns a 2005 Ford f-150. While driving 35 MPH, the vehicle stalled without warning. The contact attempted to restart the vehicle, but was unsuccessful. The contact had the vehicle towed to his home. A diagnostic appointment was scheduled with guess Ford (457 steubenville rd se, carrollton, oh 44615, [phone]). The vehicle was not repaired. The manufacturer was made aware of the failure and informed the contact that there were no recalls; therefore, the contact would have to pay in full for the repairs. The failure mileage was 76,000. Consumer stated this was the second time it stalled. Updated 12/03/18
Tl contact owns a 2005 Ford f-350. The contact was driving approximately 60 MPH, the diesel engine overheated with smoke coming from the exhaust pipe. The vehicle was driven to the side of the road. The engine was turned off, and restarted after waiting until the engine cooled down. The vehicle resumed operation. The vehicle was taken to an independent mechanic for diagnostic testing. The failure was contributed to the oil cooler and exhaust gas recirculation (EGR). The vehicle was repaired. The mechanic advised replacement of the oil pump and fuel injectors. The failure mileage was 160,000. The current mileage was 160,200.
Tl* the contact owns a 2005 Ford f-350. The contact stated that the vehicle misfired and caused the steering wheel to seize. Also, while driving various speeds, the brake pedal was depressed, but the vehicle failed to immediately stop. The vehicle was taken to formula Ford Lincoln (4318 middle rd, rutland, vt 05701, [phone]) where the cam phasers were replaced; however, the failure recurred after 176 miles. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 63,000.
Tl contact owns a 2005 Ford f-350. The contact stated that while driving at approximately 74 MPH, the vehicle stalled without warning. The failure recurred on multiple occasions. The vehicle was taken to an independent mechanic, who diagnosed that four injectors fractured. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 170,000.
Tl contact owns a 2005 Ford f-350. The contact stated while driving approximately 55 MPH, the engine stalled without warning. The contact managed to coast to an emergency lane. The vehicle was restarted. However, the failure recurred multiple times. The vehicle was not taken to the dealer for a diagnosis. The manufacturer was notified of the failure. The approximate failure mileage was 75,000.
The gas tank has a defect it epoxy liner in gas tank corrodes and plugs up the filter ejector and shut truck down and rust out filters. The truck was been driven when it shut down , took truck to Ford dealer, was told gas tank is eroded and has plug up system including injectors, will be $8000.00 to fix, that there wasnt a current recall on item, but that for know problem exist.
Engine complaints in other F-350 years
Frequently asked questions
How common are engine problems on the 2005 Ford F-350?
NHTSA has 35 complaints about the engine & cooling of the 2005 Ford F-350, 31% of the model year's 114 complaints. The component named most often is engine › diesel (6 mentions).
Is there a recall for 2005 Ford F-350 engine problems?
No. NHTSA lists no engine & cooling recall for the 2005 Ford F-350, though it has 1 recall 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-350 engine problems start?
Half of the complaints with a recorded mileage happened before about 99,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 2 fires and 1 injury to engine & cooling 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.