2005 Ford F-250 Recalls, Problems & Maintenance

The 2005 Ford F-250 has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “EGR/oil cooler failure and engine overheating.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2005 Ford F-250.

Reported to NHTSA

EGR/oil cooler failure and engine overheating

ENGINE

22 NHTSA complaints · 2010-08 → 2018-08

“F250 6.0L DIESEL WITH 85844 MILES HAD THE EGR/OIL COOLER GO BAD THE REPAIR COST 4744.00 AT THE DEALER. I HAVE AN EXTENDED WARRANTY BUT AS USUAL NOT COVERED. THIS A KNOWN PROBLEM WITH THESE 6 LITERS ALONG WITH THE HEAD BOLS BEING SUBSTANDARD AND FAULTY FICM WHICH I REPLACED AT”
— Owner report, NHTSA ODI #10795107
“TL* THE CONTACT OWNS A 2005 FORD F-250. THE CONTACT STATED THAT THE VEHICLE FAILED TO START AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTOR CONTROL MODULE FAILED AND NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #10863422
“THIS PARTICULAR MODEL AND YEAR WITH THE 6.0 LITRE ENGINE (2005 ) IS NORTORIOUS FOR THE OIL COOLER TO BLOW UP LEAVING YOU STRANDED WHEREVER. WHEN IT HAPPENED TO ME I WAS PULLING A 33FT 5TH WHEEL TRAILER AND ALMOST WRECKED. FORD KNOWS ALL ABOUT THIS FAULTY PIECE OF EQUIPMENT YET”
— Owner report, NHTSA ODI #11118168

Read all complaints on NHTSA →

Wheel cracking and tire tread separation

WHEELS

7 NHTSA complaints · 2011-07 → 2022-10

“THE WHEELS ON MY TRUCK ARE CRACKING AND BREAKING. THEY ARE 20X8 INCH FORGED ALUMINUM FACTORY INSTALLED OEM EQUIPMENT. THIS IS THE SECOND WHEEL I HAVE HAD TO REPLACE AT A VERY EXPENSIVE COST. THE FIRST ONE I THOUGHT MAY HAVE BEEN A FLUKE AS MY TRUCK HAS NEVER BEEN IMPACTED AT THE”
— Owner report, NHTSA ODI #11025201
“TIRE BEGAN TO SHIMMY, PULLED OVER FOUND NOTHING WRONG, 25 MILES LATER TIRE BLEW AT HIGHWAY SPEED CAUSING LOSE OF CONTROL. TIRE BELTS DID EXTENSIVE DAMAGE TO VEHICLE. SAME TIRE AS NHTSA RECALL NUMBER 15T-061 BUT MANUFACTURED 4 MONTHS PRIOR TO EARLIEST RECALL PRODUCTION DATE”
— Owner report, NHTSA ODI #10894721
“TL* THE CONTACT OWNS A 2005 FORD F-250. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED, THE CONTACT DISCOVERED CRACKS ON BOTH THE FRONT PASSENGER AND REAR DRIVER'S SIDE WHEELS. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS REPAIRED”
— Owner report, NHTSA ODI #10460533

Read all complaints on NHTSA →

Frame and underbody structural rust

STRUCTURE

6 NHTSA complaints · 2011-10 → 2024-04

“TL* THE CONTACT OWNS A 2005 FORD F-250. THE CONTACT HEARD A RATTLING SOUND UNDERNEATH THE VEHICLE WHILE DRIVING. THE CONTACT LOOKED UNDERNEATH THE VEHICLE AND NOTICED THAT THE BRACKETS TO THE VEHICLE WERE RUSTED AND PARTIALLY DETACHED. THE CONTACT NOTICED THAT THE FRAME”
— Owner report, NHTSA ODI #10994215
“I NOTICED THAT WHEN I HIT A BUMP THE BED OF MY TRUCK BOUNCES ABOUT TWO INCHES, WHEN I LOOKED UNDER THE TRUCK I NOTICED ALL THE SUPPORTS UNDER THE BED WERE COMPLETELY ROTTED. I HAVE ALSO HAD PROBLEMS WITH MY BRAKES. IN LESS THAN 90,000 MILES I'VE REPLACED THREE BRAKE CALIPERS”
— Owner report, NHTSA ODI #10504963
“TRUCK FRAME SEEMS TO BE ROTTING. TOLD 3-4 YEARS AT MOST BY MECHANIC. ALREADY REPLACES FUEL TANK BRACKETS, ANY RUST RECALLS AS IN ONES TOYOTA DID A WHILE AGO/ ALSO TOLD AT 1000,000 MI WILL NEED SPARK PLUG CHANGE (ONLY59000 NOW) AND THERE WAS A RECALL OF THIS PLUG REMOVAL COULD BE”
— Owner report, NHTSA ODI #11035371

Read all complaints on NHTSA →

Front suspension shimmy at highway speed

STEERING, SUSPENSION

49 NHTSA complaints · 2010-07 → 2025-01

“I RECENTLY PURCHASED A FORD 2005 F250 SUPER DUTY TRUCK. WHILE DRIVING ON THE HIGHWAY AT 70 MPH, I HIT AN UNEVEN SPOT ON THE ROAD THAT CAUSED THE FRONT END TO WOBBLE VIOLENTLY. I FELT I COULD NOT CONTROL THE TRUCK AND HAD TO APPLY THE BRAKES IMMEDIATELY. LUCKILY THERE WERE NO”
— Owner report, NHTSA ODI #10346501
“MY 2005 FORD F250 SUPER DUTY TRUCK EXHIBITS A CONDITION REFERRED TO IN FORUMS AS 'DEATH WOBBLE', IN WHICH THE TRUCK'S FRONT SUSPENSION SHAKES VIOLENTLY AT HIGHWAY SPEEDS ABOVE 50 MPH. THIS CONDITION IS GENERALLY BROUGHT ON BY EITHER OF THE FRONT WHEELS HITTING ANY DEVIATION IN”
— Owner report, NHTSA ODI #11246395
“In 2014, I got the “Ford death wobble” in the right front. VERY scary and dangerous. Trying to quickly slow down to stop it in traffic is almost as dangerous as the wobble itself. You have very little to no control with the steering when it happens. I had to repair the problem”
— Owner report, NHTSA ODI #11487504

Read all complaints on NHTSA →

Engine stall linked to fuel injection control module

ELECTRICAL SYSTEM

22 NHTSA complaints · 2010-11 → 2018-05

“TL* THE CONTACT OWNS A 2005 FORD F-250. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE RESTARTED AFTER MULTIPLE ATTEMPTS; HOWEVER, THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN”
— Owner report, NHTSA ODI #10671023
“TL* THE CONTACT OWNS A 2005 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC BUT HAD NOT BEEN DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM”
— Owner report, NHTSA ODI #10557937
“TL* THE CONTACT OWNS A 2005 FORD F-250. WHILE DRIVING 70 MPH, THE BRAKE PEDAL WAS DEPRESSED AND TRAVELED TO THE FLOORBOARD. THE CONTACT STATED THAT THE BRAKE PEDAL HAD TO BE PUMPED SEVERAL TIMES AND THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER. ADDITIONALLY, THE VEHICLE”
— Owner report, NHTSA ODI #11097019

Read all complaints on NHTSA →

Brake caliper seizure and dragging

SERVICE BRAKES

11 NHTSA complaints · 2010-10 → 2019-03

“ON SEVERAL OCCASIONS, MY F250, SUPER DUTY 6.0 DIESEL BECAME SLUGGISH AND GAS MILEAGE SUFFERED IMMENSELY. THEN, WITH ONLY 53,000 MILES, MY LEFT REAR DISK BRAKE CALIPER WAS DRAGGING AND STARTED SMOKING. AT MY COST AND ON THE LEFT REAR, I HAD FORD REPLACE THE CALIPER, PADS, BRAKE”
— Owner report, NHTSA ODI #10971695
“THIS IS THE THIRD TIME I HAVE ENCOUNTERED THIS PROBLEM, AND REPORTED THIS PROBLEM AS WELL. . BROUGHT TO FORD DEALERSHIP AND TOLD THEY DID NOT FIND ANYTHING WRONG WITH THE VEHICLE. IT CONTINUED TO HAPPEN. I BROUGHT THE TRUCK TO AN INDEPENDENT REPAIR SHOP WHO KNEW RIGHT AWAY THAT”
— Owner report, NHTSA ODI #10522391
“THE REAR BREAKS LOCK UP ON THE CALIPER PINS. THE CALIPERS AND PADS HAVE BEEN REPLACED UNDER WARRANTEE, AND THREE TIMES OUT OF POCKET. THE FORD DEALER NOW SAYS THE PROBLEM LIES IN THE CALIPER PIN, AFTER LOCKING UP BUY NEW PINS GREASE AND YOU ARE GOOD. THIS ONLY LAST UNTIL THE”
— Owner report, NHTSA ODI #11078575

Read all complaints on NHTSA →

Automatic transmission case and snap ring failure

POWER TRAIN

10 NHTSA complaints · 2010-12 → 2025-04

“NOTICED A CLOUD OF SMOKE BEHIND VEHICLE WHILE DRIVING 55 MPH ON HIGHWAY. UPON INSPECTION FOUND IT WAS LEAKING TRANSMISSION FLUID FROM HOLE IN TOP OF TRANSMISSION ONTO EXHAUST (EXACT SAME PROBLEM AS DESCRIBED IN FORD BULLETIN 05B27) HAD TO REPLACE TRANSMISSION AT 57,265 MILES AT”
— Owner report, NHTSA ODI #10811057
“2005 FORD F250 SD HAD CRACKED TRANSMISSION BECUASE OF LOW/REVERSE SNAP RING FAILURE IN THE 5R110 TORQSHIFT TRANSMISSION. FORD ISSUED A CUSTOMER SATISFACTION PROGRAM 05B27 BUT PUT AN EXPIRATION DATE ON IT. THE PROGRAM WAS NOT EVER FOR A WHOLE YEAR”
— Owner report, NHTSA ODI #10376895
“Transmission has a hole in it. Linkage inside broke and caused hole on case. Can’t use item for a core due to this. Happened while driving home from just across town”
— Owner report, NHTSA ODI #11466076

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

1,091 crashes 1990–2024

How the 1,091 occupant deaths break down

849

driver deaths

238

passenger deaths

4

not recorded by seat

1,091

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2004 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

9

complaints mentioning a crash

9

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2005 Ford F-250 reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.