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.
2005 Ford F-250 powertrain problems
moderate 10 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
10
Recalls
0
Avg fix
$2,500
When does it fail?
Of the 10 powertrain complaints filed for the 2005 Ford F-250, 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
No new NHTSA powertrain complaint has been filed on this vehicle in over 10 years — the issue may be aging out of the active population.
The failure pattern owners describe
The dominant failure is a snap ring inside the 5R110 Torqshift transmission that breaks and allows the planet gear to shift forward, fracturing the transmission housing and spraying fluid onto the exhaust—one owner's truck even sprayed fluid onto the windshield of the car behind them. This happens mostly between 90,000 and 120,000 miles, though one case occurred as early as 42,000. Ford issued internal service bulletins and a limited Customer Satisfaction Program 05B27 with an expiration date, but never recalled the truck and denies the problem to owners—one dealer told an owner they were the "first complaint" despite Ford having fielded 40+ similar cases in that area alone.
Electrical wiring failures plague these trucks unpredictably, killing the radio, windows, gauges, fuel pump, and engine control simultaneously or in sequence. One owner had a wiring recall available for their model year but was told it didn't apply to their VIN, despite having the exact symptoms.
Less common but dangerous: unintended full-throttle acceleration from a dead stop, engine stalling on deceleration with a lingering fault code even after throttle body replacement, and internal transmission damage from broken linkage or welded gears—some caught early, others discovered only after severe symptoms.
Same Ford F-250 powertrain reports on nearby years: 2008
Failure modes owners describe
Snap ring failure in 5R110 transmission causing housing damage and fluid leak
Low/reverse snap ring inside the 5R110 Torqshift transmission fails, allowing the planet gear to shift forward and break housing tabs. This creates an external transmission fluid leak through a hole in the transmission case, typically around the top, spraying fluid onto the exhaust and creating smoking and burning odor. The housing damage renders the transmission inoperable or requires replacement.
When: 90,000–120,000 miles reported by most owners; some failures as early as 42,000 miles; primarily 2004–2006 model years
Symptoms owners cite: Transmission fluid leak from hole in transmission case; Smoke coming from behind vehicle; Burning transmission fluid smell; Transmission locking up or refusing to shift; Major slip in shifting; Sudden loss of transmission function while driving
Repairs/costs cited: Transmission replacement required; one owner cited $4,000 replacement cost at 57,265 miles. Ford issued Customer Satisfaction Program 05B27 but with expiration date and no full warranty coverage. Part not covered under extended warranty.
Recalls/TSBs owners mention: Ford issued internal service bulletin and Customer Satisfaction Program 05B27 (mentioned in Ford Bulletin 05B27) but did not issue a formal recall. Ford initially denied the problem existed to some owners, despite internal communications about the issue to mechanics.
Electrical wiring harness failure affecting multiple systems
Intermittent electrical wiring problems cause multiple powertrain and vehicle electrical systems to malfunction simultaneously or independently, including engine running rough, transmission shifting issues, radio dropout, window failure, and fuel gauge failure. Owner's mechanic confirmed wiring issues. A wiring recall exists for this model year, but the owner reports their vehicle does not qualify despite having identical symptoms.
When: Recurrent failures reported daily; specific mileage not stated
Symptoms owners cite: Radio cutting out intermittently; Windows stop working; All gauges stop functioning; Transmission not shifting properly; Engine running rough; Engine cutting off unexpectedly and not restarting; Vehicle stalling in traffic; Fuel gauge inaccurate, leaving driver stranded; Check engine light (wrench light) illuminating frequently
Repairs/costs cited: Mechanic diagnosed wiring issues but repair details not specified by owner.
Recalls/TSBs owners mention: Ford issued a wiring recall for this model year, but owner's vehicle reportedly does not qualify despite experiencing the same failure symptoms.
Unintended full-throttle acceleration from stopped position
Engine suddenly accelerates to full power while vehicle is at a dead stop in Drive, causing the truck to lunge forward 10 feet despite immediate maximum brake application. This has occurred three times over two to three months. No check engine lights illuminate during the event. Ford dealer claims no awareness of the issue, but internet research revealed multiple similar complaints.
When: Multiple occurrences over two to three month period; specific mileage not stated
Symptoms owners cite: Sudden unintended full-power acceleration from stopped position; Vehicle lurches forward despite driver applying brakes; No warning lights present during event
Repairs/costs cited: No repairs mentioned; Ford dealer unable to diagnose or replicate.
Recalls/TSBs owners mention: Ford dealer service manager stated no prior knowledge of the problem.
Engine stalling on deceleration with throttle body code
Engine stalls during deceleration after 10–15 minutes of driving, with check engine light illuminating. The stall is not noticed until the driver applies the gas pedal. In turning situations, loss of engine power also eliminates power steering. Owner replaced the throttle body based on code P2104, but stalling recurred after a few months. The fault code persists.
When: After 10–15 minutes of initial driving; recurred months after throttle body replacement
Symptoms owners cite: Engine stalling on deceleration; Check engine light illuminating; Loss of power steering during low-speed turns; Recurring stall condition after repair
Codes mentioned: P2104 (Throttle Body)
Repairs/costs cited: Owner replaced throttle body; stalling resumed within months despite repair.
Transmission failure requiring replacement, recurring after repair
Vehicle stalls at various speeds with check engine light illuminating. Owner coasts to shoulder, shifts to Neutral, restarts and resumes driving. Failure recurs repeatedly. Independent transmission shop diagnosed burned transmission requiring replacement. Vehicle was repaired, but the stalling and transmission failure recurred. Specific failure cause not determined.
When: Failure mileage approximately 85,000 miles; recurrence after repair
Symptoms owners cite: Vehicle stalling at various speeds; Check engine warning light illuminating; Transmission burned; Recurring stall after transmission replacement
Repairs/costs cited: Transmission replaced at independent shop (Bolan Transmission Shop); failure recurred post-repair.
Recalls/TSBs owners mention: Manufacturer not notified of the failure.
Transmission internal linkage breakage causing housing hole
Internal transmission linkage breaks while driving, creating a hole in the transmission case. The transmission becomes unusable even as a core for rebuilding purposes.
When: Occurred while driving home short distance; specific mileage not stated
Symptoms owners cite: Hole in transmission case; Broken internal linkage
Repairs/costs cited: Transmission damaged beyond core usability.
Transmission gears welded together
Transmission gears fused or welded together, preventing normal operation. New truck at time of failure. Dealership had the vehicle for nearly three weeks with no diagnosis or explanation provided to owner.
When: Within one week of vehicle acquisition; brand-new vehicle
Symptoms owners cite: Transmission gears locked or welded together; Complete transmission failure
Repairs/costs cited: Vehicle at dealership for three weeks; no repair or explanation provided.
Recalls/TSBs owners mention: Dealership unable or unwilling to provide diagnosis or resolution.
Synthesized from 10 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
2005 Ford f250 diesel truck has for one week and transmission gears welded together. Has been back to dealership almost three weeks and no help nor explanation on what went wrong. If there is a model year problem should be know quyickly as these are used for heavy hauling. *ak
While at a dead stop, placed truck in drive and the engine suddenly accelerated to full power lunging the vehicle forward 10' while I simultaneously applied both feet to the brake for maximum stopping power. This is the third time in two to three months this has happened. No check engine lights are on. Took my car to the local Ford dealer and was told by the service manager that they have…
Had powertrain trouble with your 2005 Ford F-250?
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 F-250?
It's a documented issue but not catastrophic. 10 complaints have been filed. Repairs average $2,500 and most owners catch it before it causes a breakdown.
At what mileage does the powertrain typically fail?
Across the 8 complaints that reported odometer mileage, most powertrain failures cluster between 42,000 and 114,000 miles, with the median around 57,265. A quarter of owners report trouble before 42,000; a quarter make it past 114,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
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/F-250.
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.