FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION.
full bulletin at NHTSA ↗2005 Ford E-150 engine problems
moderate 5 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Complaints
5
Recalls
0
Avg fix
$3,100
When does it fail?
Of the 5 engine complaints filed for the 2005 Ford E-150, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Engine accounts for 19% of all owner complaints filed against this vehicle, across 4 categories tracked.
No new NHTSA engine complaint has been filed on this vehicle in over 9 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION.
full bulletin at NHTSA ↗WATCH FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP. VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE.
full bulletin at NHTSA ↗OIL FLOW FROM THE BASE ENGINE OIL PUMP.
full bulletin at NHTSA ↗GTWY501-AI MODULE REPEATEDLY RESETS DUE TO EXCESSIVE AMBIENT TEMPERATURE OF 150 F OR HIGHER, MODULE WILL NOT FUNCTION AND ALL LED'S FLASH REPEATEDLY.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 5 most recent
I was crushing at 55 MPH and I heard a loud pop that was followed by a continuous popping obviously from lost compression. I took to a local Ford dealer and they stated that this is a common problem for this type of motor to "blow spark plug". This happened without warning and is now a hardship for me
Truck engine dies while going up a hill causing truck to roll backwards.. No brakes to stop the truck. No power steering. *nm
Tl*the contact owns a 2005 Ford excursion. The contact stated that intermittently the vehicle would stall, and then immediately restart. The vehicle was taken to the dealer multiple times to diagnose the failure; however, since the technicians are unable to identify the cause of the failure, no repairs have been made. The vehicle identification number was unavailable. The failure and current…
The van would start losing power on the highway, where even if the accelerator is pushed down, the van continues to lose speed. The van eventually reaches a speed of 0 MPH and at which point the engine stalls. After waiting 20 minutes on the side of the highway, turning the engine off for 20 minutes then starting it seems to temporarily get it going, but only for another 30 minutes. Since the…
Total failure of diesel engine. Apparent defective engine design in the Ford/navistar 6l powestroke across several model years has been reported on internet. *js
Had engine trouble with your 2005 Ford E-150?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2005 Ford E-150?
It's a documented issue but not catastrophic. 5 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Based on the 5 complaints filed, engine issues most often appear around 64,672 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Ford/E-150.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.