EXHAUST SMOKE AND/OR SMELL, HARSH TRANSMISSION SHIFTS -- 6.0L.
full bulletin at NHTSA ↗2005 Ford E-350 powertrain problems
severe 4 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Complaints
4
Recalls
0
Avg fix
$2,500
1fire
When does it fail?
Of the 4 powertrain complaints filed for the 2005 Ford E-350, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 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
No new NHTSA powertrain complaint has been filed on this vehicle in over 16 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 powertrain 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.
ENGINE QUITS UPON DRIVE OR REVERSE ENGAGEMENT, OR WHEN COMING TO A STOP-TORQSHIFT TRANSMISSION.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 3 most recent
I have a 2005 Ford freestar. I was approx. 200 miles from home driving on hwy 71 n in ar,.stopped at a traffic light, and my transmission would not engage no warning lights had came on, no loss of power, noises of any kind. I bought this for a family vehicle. I have since talked with several people that have heard of this happening with the Ford freestars.*tr
I had an issue with the vehicle having a sudden miss from the engine while on the freeway. Saturday the sparkplugs and one coil pack was replaced. The vehicle was next driven on sunday evening where approx. 1/2 mile from the home the vehicle shut off without any power to the steering and brakes. Instruments lights were still working but dropped to the off position. I opened the hood and smelled…
Driving uphill on I-70 eastbound by silverthorne, co the engine simply quit. Limped to side of highway and tried to restart - nothing. Batteries are new, etc just no turning over of the engine. Thoughts are a bad ficm, which there is supposedly a recall but Ford denied that when I called this morning. Had the vehicle towed to a shop in arvada, co for diagnosis and repairs. Sounds like the EGR…
Had powertrain trouble with your 2005 Ford E-350?
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 powertrain problem on the 2005 Ford E-350?
It's a meaningful issue. 4 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $2,500.
At what mileage does the powertrain typically fail?
Based on the 4 complaints filed, powertrain issues most often appear around 136,925 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 $2,500 for powertrain 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 powertrain?
No active recalls currently cover powertrain 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-350.
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.