2005 Ford F-250 SD Problems

What owners report

Owners of this model year most often write about a violent front-end shake after hitting a bump, pothole or bridge joint at highway speed, which they describe as requiring hard braking to regain control. A second group of complaints covers 6.0L diesel engines stalling or failing to start, often with owners noting their vehicle was not covered by a related recall. Other reports involve front-end and wheel-bearing wear, cooling/EGR component work and fuel-system repairs, mostly on trucks past 60,000 miles.

1. 1
   Suspension

   Front-end shimmy or violent wobble over bumps at speed

   • 137 complaints (46%)
   • median 30,260 mi at 3.8 yrs old (126 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2005–2016

   Complaints describe the front end and steering wheel shaking hard after a bump, pothole, expansion joint or uneven pavement, usually at highway speed, and continuing until the truck slows well below 40 mph. Owners say the shake can pull the truck toward another lane, and that slowing or braking is the only way to stop it. Several report replacing tires, shocks or the steering stabilizer with only partial improvement, and dealerships often attributed it to tire pressure, tire balance or alignment or reported that nothing was found. A service bulletin on steering wheel oscillation and a vibration-related service campaign appear in the records for this generation, though the complaints do not say a repair resolved the symptom. Reported across a wide mileage range, from a few thousand miles up to over 100,000, most often on 4x4 trucks at 45-70 mph over bumps or rough pavement.

   3 related service bulletins

   What to check: Drive the truck at highway speed over a bridge joint or rough patch and watch for front-end shake. Ask whether the steering stabilizer, ball joints, tires and alignment have been serviced, and whether any steering-related service bulletin work was done.

   2 excerpts from owner complaints in NHTSA records

   “Front shakes violently at times on my 2005 Ford f-250. Feels like the whole front end of the truck is shaking apart. The only way I have found to stop it is to drastically slow down my truck, which is a huge safety hazard when other vehicles are following behind me. I sometimes have to slow from 55 MPH to 35 MPH. Updated 07/08/10 updated 07/09/10.”

   NHTSA complaint #10341408, filed 2010-07, 126,823 miles

   “Shortly after I purchased my 2005 Ford f-250 super duty pickup I experienced a violent vibration in the steering, when traveling over 55 MPH, after hitting a small bump in the road. When I brought my truck in for service and mentioned this episode. The service manager acted as though it were an anomaly, maybe the road conditions or something else. This didn't seem to be the truth, since it happened several times since then. …”

   NHTSA complaint #10188890, filed 2007-04, 30,300 miles
2. 2
   Electrical system

   Diesel engine stalls or will not restart

   Mentioned in 6 of 60 sampled complaints

   Owners describe the engine shutting off without warning while driving, sometimes restarting after a wait and sometimes not, with batteries and lights still working. A few report a failed fuel injection control module or injector-related repair, and some reference a wiring recall by campaign number while saying the dealer or manufacturer told them their vehicle was not included. Others describe hard starting or no-start conditions on the 6.0L diesel, which service bulletins address through injection control pressure diagnostics. Mostly reported between roughly 55,000 and 155,000 miles, often during steady-speed driving.

   Recall 05V2700002 related service bulletins

   What to check: Ask for service history on the fuel injection control module and injectors, and check by VIN whether the wiring recall was performed. A long crank or rough cold start on a test drive is worth investigating before buying.

   2 excerpts from owner complaints in NHTSA records

   “Ficm had to be replaced after many repairs to my f250 Ford pick up 6.0 diesel NHTSA#05v270000 recall my truck broke down on the freeway I paid $1,115.00 to fix the problem the dealer told me that it was not a warranty problem all though my truck has had this problem for a long time please advise.”

   NHTSA complaint #10217320, filed 2008-02, 17,000 miles

   “Tl- the contact owns a 2005 Ford f250. He states that while driving and with out warning the vehicle starts to stall and shuts off. He then has to pull the vehicle side and wait about 10 minutes and then turn the vehicle back on. When the vehicle is turned back on it drives fine afterwards without a problem. The dealer was contact and they to;d him that there was a recall for the vehicle but his VIN number was not included. …”

   NHTSA complaint #10282876, filed 2009-09, 60,000 miles
3. 3
   Suspension

   Hub, bearing and ball joint wear

   • 35 complaints (12%)
   • median 30,220 mi at 3.5 yrs old (31 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2005–2014

   Owners report front ball joints failing inspection, worn wheel bearings, and on 4x4 trucks vacuum hub seal wear, sometimes with repeat bearing replacement traced to water and dirt intrusion. One owner describes deteriorated cab body mounts causing the cab to bounce. Service bulletins describe a knuckle seal shield kit for trucks used in dust, mud or tar sand conditions and address ball joint friction. Reported from about 30,000 up to 140,000 miles, with bearing complaints concentrated at higher mileage.

   3 related service bulletins

   What to check: Have the front end checked on a lift for ball joint play and wheel bearing noise, and ask whether the knuckle seal shield kit was installed on a 4x4 used in dusty or muddy conditions.

   2 excerpts from owner complaints in NHTSA records

   “I have a Ford f250 sd diesel 2wd truck I have replace the front wheel bearing 4 time in 137,000 miles. The dealer says it is water and dirt intrusion. It has not caused any accedents yet but it is only a matter of time.”

   NHTSA complaint #10302572, filed 2010-01, 137,000 miles

   “Ford sd f250 4wd - like others, severe shimmy, especially on expansion joints on freeways. Can and does spook the driver. Scary moments. Dealer checked, and said steer stabilizer should be replaced?? At 61,000 k - no way. Others are saying same thing, including ball joints being worn out???”

   NHTSA complaint #10234915, filed 2008-07, 25,000 miles
4. 4
   Fuel system

   Fuel system and injector-related faults

   • 34 complaints (12%)
   • median 60,000 mi at 3.6 yrs old (31 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $1,750 (median of 8 quotes)
   • filed 2005–2014

   Owners describe intermittent check-engine lights along with repeated replacement of fuel-system and emissions parts such as the fuel injector pressure relay, EGR cooler and intercooler, plus injector replacement after stalling early in ownership. Service records include an extended warranty program on fuel injectors for 5.4L 3V engines and a bulletin on the fuel fill nozzle shutting off early. Reported from very low mileage up to about 80,000 miles, with several repairs concentrated in the 20,000-80,000 mile range.

   Recall 05V2660002 related service bulletins

   What to check: Ask whether the fuel injector extended coverage work was done and whether fuel-system parts were replaced. Note any hesitation, check-engine light or difficulty filling the tank on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2005 Ford f-250 super duty I have been having problems with this truck since jan of 2206 I brought it in for an update and it hasn't run right since then. It first started with speed bucking. So brought it back they said it was fixed on my way home it started again then in has no power than it wont shift .. This has been going on and on .. …”

   NHTSA complaint #10204495, filed 2007-09, 22,000 miles

   “Consumer purchased the vehicle, and was driving home after picking it up from the dealership. Consumer experienced a headache from a unfamiliar smell. Then, vehicle stalled in traffic, and had to be taken back to the dealer for the stalling and the smell. ......replaced failed injectors.”

   NHTSA complaint #10107132, filed 2005-01, 100 miles

Buying note. Give this truck a careful highway test drive over rough pavement and have the front suspension, ball joints and wheel bearings inspected before purchase. On diesel examples, ask for records covering injectors, the EGR cooler and the fuel injection control module, and confirm by VIN which recalls and bulletins were completed.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.