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 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2005 Ford f-350. While attempting to start the vehicle, it failed to start. The vehicle was towed to an independent mechanic who diagnosed that the fuel injection control module, sensor, and turbo hoses failed and needed to be replaced. The vehicle was repaired. A dealer was not contacted. Also, while driving 30 MPH, the engine began to rev and the contact had to brake to stop the vehicle from surging forward and colliding with the preceding vehicle. The vehicle continued to surge as the contact drove. The contact pulled over and turned off the vehicle. The contact was unable to restart the vehicle. The vehicle was towed to an independent mechanic who diagnosed that the injection control pressure sensor failed and needed to be replaced. The vehicle was repaired. A dealer was not contacted. …
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 approximately 65 MPH, the engine seized without warning. There were no warning indicators illuminated. The vehicle was towed to leif johnson Ford (501 e koenig ln #1, austin, tx 7875[phone]) where it was diagnosed that the fuel liner in the fuel tank caused the vehicle to seize. The fuel tank was corroded and clogged the injectors. The contact stated that the fuel tank, fuel injectors, and fuel filters needed to be replaced. The vehicle was not repaired. The manufacturer acknowledged the failure, stated that the vehicle was not included in a recall, and did not offer any further assistance. The approximate failure mileage was 120,000.
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.
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.
Tl* the contact owns a 2005 Ford f-350. While walking towards the parked vehicle, the contact noticed that the rear portion of the fuel tank was separated from the frame due to a rusted fuel tank strap. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The VIN was unknown. The approximate failure mileage was 174,000.
While driving down the highway(45-55mph) vehicle dash lights, radio, windows all stop working. They come back on randomly. No change to little change when re-starting. Vehicle also loses power and the engine seems to pause and go, over and over like it's struggling. I've taken it to several Ford certified mechanics who are baffled.
Came up with a code to replace t.p.s. I replaced tps now vehicle is having problems idling . I contacted Ford explained to them my situation. I was told by 3 different people that whenever people with a 6.8 v10 have the code to replace t.p.s they end up replacing the whole e.t.b. Is there a recall for the throttle body ?
Tl* the contact owns a 2005 Ford f-350. While driving 65 MPH, the vehicle decelerated on its own. The vehicle was taken to an independent mechanic who diagnosed that the fuel system needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was 125,900.
Power surge. Stopped waiting at light felt like I was hit from behind, very quick unexpected surge forward, it also occrures while driving but the effect is not strong, more noticeable when backing.
Fuel System complaints in other F-350 years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-350?
NHTSA has 36 complaints about the fuel & propulsion system of the 2005 Ford F-350, 32% of the model year's 114 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2005 Ford F-350 fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 99,000 miles, and 9% 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.