Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Lincoln Aviator owners, lightly cleaned up (personal details are redacted by NHTSA).
I noticed a crack on the back panel of my tailgate. There was no accident or incident and since then I have noticed at least 3 other cars in my small town with the same defect. I have written to Ford and gotten no response. From what I have seen on the internet, this is not an isolated problem. I feel that Ford/Lincoln should recall the affected models of car (including Ford explorers) and make these repairs. The mechanism that keeps my tailgate window closed and locked is also broken and I think it is directly related to the crack in the tailgate. This compromises our safety in the car by making the car unable to be locked properly. Someone could easily get into the car from the tailgate and steal anything in the car, steal the car itself, and pose an immediate threat to our personal safety.
When purchased used 2 yrs old [redacted], I noticed a crack in the middle of the liftgate. I have owned this vehicle for almost 7yrs and have taken very good care of it, but I now have 3 cracks in the liftgate. It seems to be very thin across the bottom of the back window and every time you open and close the window, it puts stress across the bottom of it. This should be a recall because there are a lot of other owners with the same problem and obviously this is a defect!! Updated 4/19/2016
While parked at the gas station getting ready to pump gas the rear window exploded, glass shattered everywhere, left hinge cracked and frame around liftgate bend and curled up. My rear liftgate has the same cracked as previously reported. I replaced the entire liftgate in 2011 & on the new liftgate the same crack came back
Transmission shift problems= we where OK when truck was on garage and just use it as weekends,but everything change when we stared to use it on daily basics transmission begin to slip and now lately begin to pull and back and forward and o/d sensor light up and afraid the rear shift go off any minute... And add up the rear panel just broke for the 2th time... It begins to make funny noise on rear axle,I very disappointed after paid closed to 20,000 dollars I want to return it to dealer but nobody wants to take charge. No fire or property damage but I not waiting to happen to me.
Design flaw. See NHTSA service bulletin number: 0485, date: 1/1/05, item number: 10008546. Design flaw acknowledged by Ford/Mercury. Repaired once by dealership, but now refuses to make repair after structure has again cracked allowing water access to structure, possibly causing electrical shortage, which could possibly cause accident if driving. Currently applying tape to body structure. Filed complaint with bbb, but negative results. Stated that even though a design flaw, their regulations & policies do not cover the above parameters unless within the warranty limit of vehicle.
One morning I noticed that a crack had appeared on the back of my vehicle on the lift gate right by the Lincoln emblem. I called and spoke to the dealership and they advised me it was a common occurrence that happens for no reason on Lincoln aviators of certain years. Now all of a sudden the lift gate hinge on the right side has slightly shifted and I have not even opened it in months. This I was notified is also another common defect on these vehicles! I literally am scared to even open the back lift gate now and nothing has happened to cause either of these issues.
No accident or anything. All of a sudden a vertical crack down the center of the back plastic piece on the right side of the emblem. The window hinges also started to fall apart. Funniest thing is that I can only purchase the parts from Ford and there is a different price for the right hinge ($40.00) and the left hinge ($46.95) wtf? Of course they are just plastic pieces also...sure wish Ford would take responsibility for this one - I mean page after page of the same complaint for a very expensive SUV - you would think they would fix it!!
Owner of 2005 Lincoln Aviator (acquired late 2006)kept exclusively in garage. Currently has 39,500 miles. A vertical crack has recently appeared near the emblem (right side) on the rear liftgate panel below the rear window. The entire liftgate portion which contains the window and the emblem has to be replaced. The vehicle is no longer under warranty, and as previously stated the dealership states that Ford/Lincoln will not stand behind its vehicle. Also, it seems the crack May prevent the from closing securely.
The hinges that hold the liftgate glass have broken and are no longer holding the rear liftgate window in place properly. I can no longer open the window because I will not be able to close it. I took it to the dealer and event though they acknowledge the fact that this is an issue on Lincoln aviators and that they have had to fix numerous Aviator in the past for this same issue they will not cover the repair if the vehicle is out of warranty.
Rear liftgate panel cracked vertically next to emblem under liftgate glass after warm day and a cool night. I called the dealer and they told me that they can repair it at my cost and they were not responsible for the repairs even though they were aware of this happening to numerous Aviator's and mountaineer and it happened through no fault of my own, and they believe the part to be defective.
Body complaints in other Aviator years
Frequently asked questions
How common are body problems on the 2005 Lincoln Aviator?
NHTSA has 28 complaints about the body & structure of the 2005 Lincoln Aviator, 55% of the model year's 51 complaints. The component named most often is body (25 mentions).
Is there a recall for 2005 Lincoln Aviator body problems?
No. NHTSA lists no body & structure recall for the 2005 Lincoln Aviator. 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 Lincoln Aviator body problems start?
Half of the complaints with a recorded mileage happened before about 72,000 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.