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 Five Hundred owners, lightly cleaned up (personal details are redacted by NHTSA).
The engine keep going into limp mode. The car stalls out while at lights an stop signs, power steering goes out on highway an other roads making it impossible to steer or steer out of others ways, limp mode causes car to not be able to keep up with traffic on highway and other roads. Engine jerks forward an shifts irractically an shifts an downshifts hard.
I was in heavy traffic and the car just stalled out on me while sitting at a light. Had to put my hazards on and try to restart car, restarted and then as soon as I put it into drive it stalled again. This happened 3-4 times until I could move to the next light and stop and go through the whole process all over again. Finally got on the highway and got home. Thought it was a fluke. Happened a second time while picking up children from daycare. Stalled out while at low RPM and would not restart. Had to have it towed. Had fuel filter replaced. Happened a third time at the store. Had to have it towed. Towed it to the dealer and the dealer spent over 6 hours to come to the conclusion that throttle body needed to be cleaned and PCM reprogrammed/updated. Without much confidence, they returned the car to me and said they could not replicate the problem. …
Suspension: continuous rattle issues in the rear suspension. Bushings? Sway bars?? Who knows. No one can seem to pinpoint the problem. Happens only during driving. Consistent noise from the rear. Fuel: problems with fuel sensor. Failed reading. All gauges light up. Run OBD and all fluid levels / pressure fine. No reason for the failure. Dealership told me the throttle body was an issue and the sensor inside same. However, after numerous web based searches I found that throttle body issues are definitely an issue. Found that removing the air cleaner box for filter replacement can cause sensor issues. Why? Since my last oil change I have had at least three failures here. This is dangerous, expensive and should be taken care of.
I will never buy another Ford vehicle ever again!!!!!! I own a 2005 Ford Five Hundred there was a recall in 2012 on the throttle body, a Ford dealer supposably cleaned the throttle body, well now its not driveable. We have since talked to several Ford dealers including Ford motor company , they all said it was our responsibility to fix the problem. I do not think it should be my responsibility to pay for this since the part was recalled !!! The car could stall at anytime while driving putting myself and my family at risk, I don't think much of this automobile company for not standing behind there product, I will never recommend a Ford vehicle to friends,family or even my worst enemy never never again!!!!
Tl* the contact owns a 2005 Ford Five Hundred. While reversing out of the driveway, the contact noticed a puddle of fuel on the garage floor, the vehicle was taken to an independent mechanic where it was diagnosed that the fuel line was detached and needed to be replaced. The vehicle was repaired. The vehicle was not taken to a dealer. The manufacturer was notified of the failure and informed the contact that the VIN was not included in a recall. The contact was referred to NHTSA. The approximate failure mileage was 101,000. Consumer stated gas was leaking. Even though it was repaired it happened again. Updated 11/20/18
Electronic throttle body a major complaint and causes the car to have no throttle response. Elderly mother got stuck on a hill and could not get car rest of the way up the hill to safety. Page after page of this complaint on internet. Ford aware of these issues and still refuses to launch a recall. Part cost $500+ for the part and dealer wants another $300+ for install. Absolutely disgusting to have elderly or women with infant children stuck on roadways with this issue. Will never but Ford again based on my experience with this issue and them turning their back on this known problem.
At low speeds, when turning and when accelerating from a stop, the car will shake, lunge and then shut off. Sometimes it just shakes and hesitates and then keeps going. Sometimes it takes a while to get it running again. It always happens when the car is in motion. A couple of times this happened, the transmission error codes were displayed. I have had the transmission checked out and it was fine.
Takata recall my car has a fuel leak problem and fuel tank is damage to weld defect cide: p04442. Also previous own installed a aftermarket remote car starter. Now my car has trouble starting ever after I replaced the starter. Problem might be the (ECU) engine control unit now working properly.
The fuel system is malfunctioning. The fuel tank has a crack caused by a welding point on the fuel tank was broken loose. Over time I saw my fuel gauge drop dramatically. This causes me to get gas more often.
This car have a large amount of complaint of the lurching due to a sudden malfunctioning throttle body which cause irregularity in the speed and May cause crashes and might end to body injuries or fatality.
Related recalls
Fuel system, gasoline › Storage › Tank assembly › Mounting
On certain passenger vehicles, the straps that secure the fuel tank to the vehicle body May break, causing the fuel tank and fuel tank heat shield to drop on the driveshaft (all wheel drive vehicles) or exhaust system (front wheel drive vehicles).
Remedy: Dealers will replace both fuel tank straps. The recall began on December 1, 2005. Owners May contact Ford at 1-800-392-3673.
Fuel System complaints in other Five Hundred years
Frequently asked questions
How common are fuel system problems on the 2005 Ford Five Hundred?
NHTSA has 44 complaints about the fuel & propulsion system of the 2005 Ford Five Hundred, 9% of the model year's 510 complaints. The component named most often is delivery (2 mentions).
Is there a recall for 2005 Ford Five Hundred fuel system problems?
Yes — NHTSA recall 05V-515 (mounting, Nov 9, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2005 Ford Five Hundred fuel system problems start?
Half of the complaints with a recorded mileage happened before about 101,000 miles, and 8% 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.