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2005 Ford F-350 Recalls, Problems & Maintenance

The 2005 Ford F-350 has no open NHTSA recalls. Owners report 5 recurring issue clusters, led by “Fuel tank liner delamination clogging fuel system.” 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-350.

Reported to NHTSA

Fuel tank liner delamination clogging fuel system

FUEL SYSTEM, DIESEL

17 NHTSA complaints · 2009-05 → 2017-09

“TL* THE CONTACT OWNS A 2005 FORD F-350. THE CONTACT STATED THAT THE FUEL TANK ON THE VEHICLE WAS ERODING AND CAUSING THE VEHICLE TO LOOSE POWER INTERMITTENTLY WITHOUT WARNING”
— Owner report, NHTSA ODI #10375484
“I HAVE A 2005 FORD F-350 WITH A POWERSTOKE. IT ONLY HAS ABOUT 100,XXX MILES ON IT BUT THE FUEL TANK DELAMINATED AND CAUSED FIVE INJECTORS TO GO BAD THIS IS A SAFETY CONCERN”
— Owner report, NHTSA ODI #10396604
“FUEL TANK LINING IS PEELING OFF CAUSING FAILURE TO INJECTORS/ PUMP AND FILTERS. CAUSES POWER LOSS IN TRAFFIC WHICH IS UNSAFE. THIS HAS HAPPENED TO ME THREE TIMES SINCE AUGUST 2010 IN INTERSTATE TRAFFIC”
— Owner report, NHTSA ODI #10362619

Read all complaints on NHTSA →

EGR cooler and oil cooler failure causing overheating

ENGINE AND ENGINE COOLING

21 NHTSA complaints · 2010-04 → 2014-06

“TL* THE CONTACT OWNS A 2005 FORD F350 SD. THE CONTACT STATED THAT WHILE DRIVING UPHILL, THE VEHICLE OVERHEATED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THEY STATED THAT THE TURBO NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED”
— Owner report, NHTSA ODI #10504952
“TL*THE CONTACT OWNS A 2005 FORD F-350 SUPERDUTY. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 60 MPH, THE TEMPERATURE GAUGE INDICATED THAT THE VEHICLE WAS RUNNING HOT. HE DROVE ONTO THE EMERGENCY LANE AND CHECKED THE COOLANT WHICH HE FOUND TO BE VERY LOW”
— Owner report, NHTSA ODI #10353663
“TL* THE CONTACT OWNS A 2005 FORD F350. THE CONTACT STATED THAT THE EGR OIL COOLER FAILED AND NEEDED REPLACING. THE MANUFACTURER WOULD NOT PROVIDE ANY ASSISTANCE DUE TO THE VEHICLE BEING OUTSIDE OF FACTORY WARRANTY”
— Owner report, NHTSA ODI #10350748

Read all complaints on NHTSA →

Tire tread separation and sidewall failure

TIRES

7 NHTSA complaints · 2009-05 → 2019-02

“TL* THE CONTACT OWNS A 2005 FORD F-350 SD EQUIPPED WITH MICHELIN TIRES, SIZE: LT245/75/R17 TIRES(N/A). THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH, THE HOOD ON THE TRUCK, BEGAN TO VIBRATE IN A VIOLENT MANNER”
— Owner report, NHTSA ODI #10510938
“COMPLETE TREAD SEPARATION AROUND ENTIRE SIDEWALL ON LEFT (DRIVER) REAR CONTINENTAL CONITRAC TR LT275/70R18 125/122S TIRE WHILE DRIVING AT 55MPH ON PAVEMENT. THE VEHICLE WAS A FORD F-350 SUPER DUTY PICKUP CARRYING NO LOAD”
— Owner report, NHTSA ODI #10268421
“TL* THE CONTACT OWNS A 2005 FORD F-350 WITH CONTINENTAL TIRES, TIRE LINE SIZE 275/70/18. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, HE HEARD A LOUD NOISE AND THE VEHICLE STARTED JERKING VIOLENTLY”
— Owner report, NHTSA ODI #10416280

Read all complaints on NHTSA →

Steering wheel and front-end shimmy over road bumps

STEERING, SUSPENSION

55 NHTSA complaints · 2009-04 → 2024-02

“My 2005 F350 Diesel Pick up has suffered from the Ford death wobble on and off for the last 15 years. While navigating a left hand corner at speeds over 40 it begins to shake uncontrollably after hitting a small bump or pot hole until speed is reduced to 30mph or less”
— Owner report, NHTSA ODI #11530347
“2005 FORD F-350 4X4 DUALLY WITH SEVERE FRONT END SHAKE AT AROUND 50 MPH AND HITTING A BUMP IN ROAD. MUST SLOW TO 35 MPH TO STOP SHAKING. FORD DEALER STATED PROBLEM WAS DUE TO IMPROPER TIRE PRESSURE. HAVE REPLACED STEERING STABILIZER, AND DRAG LINE, TO NO BENEFIT AS OF YET”
— Owner report, NHTSA ODI #10284238
“1. IF I DRIVE OVER A BUMP IN THE ROAD AT 50MPH OR FASTER. 2. FRONT END SHIMMY. THE FRONT OF MY TRUCK SHAKES VIOLENTLY AND THE BRAKES HARDLY WORK TO GET THE TRUCK SLOWED DOWN. THE SHAKING IS SO VIOLENT THAT I LOSE CONTROL OF THE TRUCK”
— Owner report, NHTSA ODI #10265894

Read all complaints on NHTSA →

Engine stall linked to fuel injection control module

ELECTRICAL SYSTEM

35 NHTSA complaints · 2009-09 → 2024-06

“TL*THE CONTACT OWNS A 2005 FORD F-350 SUPERDUTY. THE CONTACT SAID THE VEHICLE BECAME VERY DIFFICULT TO START AND WHEN IT DID START IT WOULD STALL. THE DEALER INSPECTED THE VEHICLE AND FOUND THAT THE FAILURE WAS CAUSED BY THE FUEL INJECTOR CONTROL MODULE”
— Owner report, NHTSA ODI #10370905
“TL* THE CONTACT OWNS A 2005 FORD F-350 SD. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE TECHNICIAN WAS UNABLE TO DIAGNOSE THE FAILURE”
— Owner report, NHTSA ODI #10513270
“TL* THE CONTACT OWNS A 2005 FORD F-350 SUPER DUTY. THE CONTACT STATED THAT AFTER REFUELING, THE VEHICLE WOULD NOT RESTART. THE CONTACT HAD TO APPLY STARTING FLUID IN ORDER TO START THE VEHICLE. THE FAILURE WAS EXPERIENCED APPROXIMATELY THREE TIMES”
— Owner report, NHTSA ODI #10448626

Read all complaints on NHTSA →

Issues on other model years

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.

12

complaints mentioning a crash

11

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-350 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.

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