2005 Ford F-250 Problems

What owners report

Owners of this model year most often report two things: a violent front-end shake or steering-wheel shimmy after hitting a bump at highway speed, and engine stalling or no-start conditions on the 6.0L diesel, often traced to the fuel injection control module or EGR/oil cooler. Complaints arrive across a wide mileage span, from a few thousand miles to well past 150,000, and the steering/suspension shake is usually described as sudden and repeatable rather than gradual.

1. 1
   Steering

   Front-end shake or steering shimmy over bumps

   • 41 complaints (28%)
   • median 36,000 mi at 5.5 yrs old (35 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2007–2025

   Owners describe driving at highway speed, hitting a bump, expansion joint or rough pavement, and then having the front end and steering wheel shake violently until the truck is slowed to roughly 20-30 mph. Several report the truck changing lanes or losing steering control during the event. Complaints describe dealers often unable to duplicate the problem; some owners were told to check tire pressure, and others had tie rod ends, shocks or steering stabilizers replaced without the shake going away. A Ford service bulletin describes steering wheel oscillation and wobble and outlines diagnostic steps. Reported from as little as a few hundred miles up to about 180,000, most commonly at highway speeds over bumps.

   1 related service bulletin

   What to check: Ask whether the steering stabilizer, drag link, tie rod ends or track bar have been replaced and whether any wobble persists. A highway test drive over expansion joints and rough pavement is the most direct check.

   2 excerpts from owner complaints in NHTSA records

   “My Ford f250 has a very dangerous wobble when I hit a bump on the highway. I have checked the tire pressure and all four tires are fine. After doing some research I had found that this is a on going problem with the Ford sd trucks. Something has to be done or someone is going to get killed due to a bad accident. Every dealer that I talk to has never heard of this problem but yet I see it posted all over the internet. I am very upset and I am going to take legal action.”

   NHTSA complaint #10429550, filed 2011-10, 129,000 miles

   “2005 Ford f250 with approximately 19,100 miles. Original factory tires, suspension- no modifications. Tire pressure set to factory door label specs. On monday, 8-19-2019 while on I-95, travel speed at about 60 m.p.h., I drove over a bridge expansion joint & the entire truck started shaking violently. Steering wheel was vibrating/shaking making it difficult for me to maintain control of the truck in my established lane and nearly took out several cars in the adjacent lanes nearly causing multi-vehicle collision. …”

   NHTSA complaint #11246578, filed 2019-08, 19,100 miles
2. 2
   Engine

   Engine stalls or will not restart (FICM, EGR, oil system)

   • 37 complaints (26%)
   • median 100,000 mi at 9.0 yrs old (35 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2007–2025

   Complaints describe the engine quitting without warning while driving, sometimes with the check engine light and sometimes with none, followed by no-start or hard-restart conditions. Owners frequently name the fuel injection control module, EGR valve and EGR cooler, high-pressure oil pump or pressure regulator, and a chafed injector wiring harness. Dealers are described as replacing the FICM or oil components, occasionally unable to duplicate the stall, and owners note the truck was not covered by the electrical system recall they had heard about. Spread widely, from about 16,000 to over 200,000 miles, often reported on the 6.0L diesel.

   What to check: Ask for service records on the FICM, EGR cooler and oil cooler, and whether the injector harness has been inspected for chafing. Check for rough running, white or blue smoke under load, and any stored check-engine codes.

   2 excerpts from owner complaints in NHTSA records

   “My 2005 Ford F-250 6.0l diesel lost acceleration onto a highway. It stalled and started billowing white smoke from the exhaust. After a few moments it slowly accelerated, but nearly caused an accident as cars ran up onto us. The engine was missing and we made it to an intersection to pull off of highway. We stopped and restarted the engine and it started running normally. However, it happened again once we were on the road. …”

   NHTSA complaint #10329550, filed 2010-05, 66,817 miles

   “Engine stalled without warning driving in traffic while weaving in and out of traffic trying to avoid hitting other vehicles or them hitiing me. A dangerous, intense moment trying to get my truck off the road with no power steering or power brakes. This truck may or may or m ay not start. No crank/no start, no start/cranks, no start/bucking and stalling engine. These issues relate to the injector wiring harness due to chaffing and crushing, a very time consuming task. Technician verified the harness is worn and wires are exposed. …”

   NHTSA complaint #10794755, filed 2015-11, 121,000 miles
3. 3
   Engine cooling

   Coolant loss and head gasket or EGR cooler trouble

   • 14 complaints (10%)
   • median 66,817 mi at 8.3 yrs old (13 state mileage)
   • filed 2010–2021

   Owners report white steam from the exhaust, rising temperature, coolant seepage and excessive coolant consumption, in some cases after the EGR cooler or oil cooler work. Complaints describe stretched head bolts and failed head gaskets on the 6.0L diesel, with repair quotes from dealers and extended warranty disputes. Some note an exhaust tick or pop noise that a bulletin addresses. Most often reported between roughly 85,000 and 120,000 miles, with some cases near 40,000.

   1 related service bulletin

   What to check: Check the coolant level and look for residue or steam at the exhaust, and ask whether the EGR cooler, oil cooler or head gaskets have been replaced. A pressure test before purchase is worthwhile.

   2 excerpts from owner complaints in NHTSA records

   “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 the cost of 525.00 and doing the work myself. I have tried to resolve this with Ford and my warranty company warranty direct to no avail. …”

   NHTSA complaint #10795107, filed 2015-11, 85,844 miles

   “While driving on m-37 I noticed white steam coming out of exhaust. Noticed engine temp rising. I stopped cooled engine and brought truck home, where it has been since then. This is a problem Ford motor company has known about since 2005. The engineering department identified this design flaw back then and still to this day refuse to help compensate consumers for repairs. The head bolts stretch allowing for the head gaskets to fail. …”

   NHTSA complaint #10645079, filed 2014-10, 118,150 miles
4. 4
   Transmission and drivetrain

   Transmission snap ring failure and fluid leak

   • 5 complaints (3%)
   • median 48,000 mi at 5.0 yrs old (5 state mileage, few)
   • filed 2004–2015

   Complaints describe a snap ring inside the 5R110 TorqShift transmission failing, which lets internal parts shift, breaks the housing and produces an external transmission fluid leak, in some cases spraying onto the exhaust. Owners report the transmission locking up or requiring replacement, and reference a Ford customer satisfaction program on this condition. Some describe transmission gears welding together shortly after purchase. Typically reported between about 40,000 and 120,000 miles.

   What to check: Look for transmission fluid leak traces around the case and on the exhaust, and ask whether any snap ring or transmission work was done under the customer satisfaction program.

   2 excerpts from owner complaints in NHTSA records

   “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 a cost of $4,000.00. Ford would not warranty it.”

   NHTSA complaint #10811057, filed 2015-12, 57,265 miles

   “A snap ring inside the transmission fails allowing the planet to shift forward breaking housing tabs off causing a external leak of transmission fluid to other vehicles driving down the road,no warning a transmission may lock up causing safety concerns, Ford has recognized the situation before and sent a internal notice to mechanics to fix the problem, no recall was ever sent. …”

   NHTSA complaint #10279105, filed 2009-08, 114,000 miles

Buying note. Check the steering and front suspension on a highway drive over bumps, and get service records for the FICM, EGR cooler and transmission before committing. A pre-purchase inspection by a mechanic familiar with this drivetrain is a practical step given the range of issues owners report.

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.