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-450 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2005 Ford f-450 SD. While driving 35 MPH, the engine stalled. The vehicle was taken to an independent mechanic, who diagnosed that the fuel injection and motor needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 34,772.
In 2006 34,918 miles Ford had to replace the fuel pump on my 2005 f450 truck. They also replaced the injectors several times also replaced the turbo. They have found rust in the system, this is caused from the liner in the tank has fallen apart. The truck runs real bad, bucking and losing power. The mileage on the truck now is 125000. I have changed my fuel filter many times and within mins after changing the bucking starts. I live in the san francisco area and I know they regulate the fuel. The shop wants $4000.00 to change my injectors, then $2100.00 to change the tank. This is said when a fuel tank falls apart in side and they want you to pay the cost. I paid $50000 when I bought this f450. I know I will not buy another Ford product if I have to pay this bill. My 3 GMC trucks are running great, and so was our Dodge. I hope you can help me with on going problem. [redacted]
Sept. 9, 2008 - truck started missing changed fuel filter when in shop for normal service March 18, 2009 - truck stalled and would not start, towed to shop, did diagnostics , regular service, and put on fuel regulator oct. 12, 2009 - truck missing and overheating, replace fuel filter and radiator tank aug. 11,2010 - truck missing again would not start , smoking, towed to cauthorns,, then to Ford garage. Warranty work completed on truck, they thought head gaskets blown, replaced EGR cooler and oil cooler, cleaned turbo, , replace fuel filter and replaced battery. Aug. 17, 2010- vehicle towed to cauthornes auto from Ford garage to have fuel tank replaced due to peeling and slivers in tank. Seeing as how this is the third truck we have had to have the fuel tank replaced on we have saved the old fuel tank and have it on hand at our shop for inspection.
I have a 2005 Ford f-450 that was loosing power going down the road. I had just replaced the fuel filters about two thousand miles before. When I removed the frame mounted fuel filter it was full of silver metal flakes. I called the service manager at Ford and was told it was delamination of the fuel tank. Of course my three year / thirty six thousand was out . The one hundred thousand on my motor covered everything but the fuel lines and fuel tank. I think this is bull and Ford should be responsible for this problem. By the way I've seen many complaints on this problem. My truck has fifty eight thousand miles on it . Ford told me it was costing me about one thousand dollars to fix it. To me its just going to be a temporary fix from what I can tell from all the complaints.
10/5/2010 brighton,mi my truck started to blow white smoke and the engine stopped running while driving down the road. I had it towed to my dealer and was told it has a delamination problem in the fuel tank and the cause was from bio-diesel contamination and I would now need to replace or reseal the tank and install a new fuel pump along with one new injector at a cost of $2643.00 plus tax. I had the repairs done because I need the truck for work I also saved the old parts. Hopefully Ford(if they want to sell me another truck in the future) will participate in this repair.
I own two 2005 f450 mason dumps and the fuel tanks in both are flaking apart inside and destroying both of my engines !! The repairs and damage are endless and im sick to hear Ford is aware of this and has not made any attempt to notify me. Had I known this was an issue I would have asked them to replace both with an approved plastic tank prior to my lines, injectors, filters and who knows what else getting clogged and destroyed by this flaw. The repair fees and lost wages due to this known problem is a disgrace and I would like to know my options against Ford. I currently own 4 Ford trucks, will all do the same ??
Tl* the contact owns a 2005 Ford f-450 SD. The contact stated that the fuel tank was delaminating and causing fuel to become clogged. The dealer was contacted and denied any assistance with repair to the vehicle. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 45,000 and the current mileage was 70,000. The VIN was unavailable. The consumer stated the vehicle was repaired, but not at a Ford dealership, since the refused to acknowledge the fuel tank delaminated into the fuel and then plugged the fuel filter more than once. Updated 08/26/11
Tl* the contact owns a 2005 Ford f-450 SD. The contact stated that while driving 30 MPH, the vehicle began to hesitate intermittently. The contact removed the fuel tank and noticed that the lining of the fuel tank had started to peel and become mixed with the fuel. The fuel filter was also full of the inside lining of the gas tank. The dealer was notified and admitted there was a problem with the tanks peeling however stated it was the type of fuel the contact was using. The manufacturer was notified of the issue but offered no assistance. The failure and current mileages were 66,000.
Tl* the contact owns a 2005 Ford f-450 diesel. The contact stated that while driving 60 MPH the vehicle stalled without warning. The vehicle was taken to the dealer, who diagnosed that the interior paint of the fuel tank was delaminating. As a result, the fuel tank, fuel lines, fuel pump, fuel injectors, and filters needed to be replaced. The manufacturer was made aware of the failure and offered no assistance because the vehicle was no longer under warranty. The vehicle was not repaired. The failure mileage was 40,000 and the current mileage was 70,000.
Tl* the contact owns a 2005 Ford f-450 SD. The contact was driving 45 MPH when the vehicle stalled without warning. The vehicle was towed home and the dealer was notified who informed him to check the fuel filter drain plug and then drain the fuel out. The dealer stated that if he should notice paint flakes, which would be the lamination of the inside of the fuel tank, he would have to replace the fuel tank, pump and clean out the fuel lines. The manufacturer was not notified of the failure. The failure mileage was 85,000.
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-450 SD years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-450 SD?
NHTSA has 24 complaints about the fuel & propulsion system of the 2005 Ford F-450 SD, 60% of the model year's 40 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 2005 Ford F-450 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-450 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 48,000 miles, and 9% before 25,000 miles.
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.