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moderate Owners of the 2005 Ford E-150 have filed 4 NHTSA complaints about the fuel system at roughly $1,200 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See fuel system across all vehicles →
Of the 4 fuel system complaints filed for the 2005 Ford E-150, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
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.
All 2 active fuel system recalls on this vehicle land at critical or severe — none classified moderate.
No new NHTSA fuel system complaint has been filed on this vehicle in over 15 years — the issue may be aging out of the active population.
A fuel leak in the presence of an ignition source may result in a fire.
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
The manufacturer has issued service bulletins covering fuel system 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 ↗FUEL CONDITIONER. LOW POWER, POOR FUEL ECONOMY, FUEL GELLING IN COLD WEATHER, EXCESSIVE WHITE SMOKE ON COLD START, HARD START, OR COKING OF COMPONENTS EXPOSED TO EXHAUST.
full bulletin at NHTSA ↗SLOW FUEL FILL ON VEHICLES WITH A 4.6L OR 5.4L ENGINE AND MID-SHIP FUEL TANK.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
Tl*the contact owns a 2005 Ford econoline. The contact stated that she could smell fuel inside the vehicle and smoke escaped from the tailpipe. The dealer replaced the liner on the fuel tank twice. The dealer stated that the diesel fuel ate through the lining. The failure mileage was approximately 50,000 and the current mileage was approximately 78,000.
The vehicle, a Ford e350 6.0l diesel would lose power while on the highway and come to a complete stop in the middle of the road. After waiting about 20 minutes, sometimes would start up but most of the time would have to be towed. This would occur whenever the vehicle is driven for more than 20-40 miles when the engine is warmed. This has occurred a total of over 15 times, each failure having a…
It's a documented issue but not catastrophic. 4 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
Based on the 4 complaints filed, fuel system issues most often appear around 48,500 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.
Independent shops typically charge around $1,200 for fuel system 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.
Yes — 2 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.