This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.
full bulletin at NHTSA ↗2005 Ford Taurus body problems
severe Owners of the 2005 Ford Taurus have filed 17 NHTSA complaints about the body, typically surfacing around 103,000 miles at roughly $1,500 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See body across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$1,500
| Model year | body complaints |
|---|---|
| 2005 Taurus (this page) | 17 |
| 2006 Taurus | 12 |
| 2007 Taurus | 7 |
| 2008 Taurus | 3 |
3crashes
1fire
1injury
What stands out
Of the 13 model years of Ford Taurus we track for body problems, this one carries the most owner complaints on file — 17.
No new NHTSA body complaint has been filed on this vehicle in over 18 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 body 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.
Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
full bulletin at NHTSA ↗Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
full bulletin at NHTSA ↗WELD BONDING PROCEDURE.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Water leaks into the floorboard and interior, especially on the passenger side, are the most frequent complaint. Multiple owners report soggy carpets and rust buildup inside the glove box after rain. Dealers have blamed normal moisture or charged owners to investigate, and no recall has been issued despite owners claiming the problem is widespread across Taurus and Sable models.
Cold-weather door latch freezing is a genuine safety hazard. Owners report latches won't close in sub-20°F temperatures, doors spontaneously pop open while driving, and doors lock while the engine runs to warm up. One owner had the latch replaced on a separate Taurus two years earlier.
Floor pan rust perforation is severe in some vehicles. One owner documented holes so large only carpet prevented feet from dropping through. Frame rust-out has rendered at least one vehicle unsafe at 75,000 miles.
Less frequent but documented: A-pillar weld cracks with persistent dashboard noise despite multiple repair attempts and body shop rework; paint bubbling and peeling on roof and bumpers; spontaneous trunk opening; and static electrical shocks when exiting the vehicle.
Same Ford Taurus body reports on nearby years: 2006
Failure modes owners describe
A-pillar structural weld failure and noise
A-pillar weld cracking with associated dashboard creaks. Windshield stress fractures observed. Multiple dealership attempts to isolate noise failed; body shop performed weld repair work.
When: Early ownership, 6,958–7,001 miles
Symptoms owners cite: Creaking noise from right front dashboard; Windshield stress fractures; Foam applied between dashboard and windshield did not resolve issue
Repairs/costs cited: Foam applied initially; later removed upper dash and garnish trim, A-pillar weld repaired by body shop, right A-pillar trim replaced, air bag removed and inspected. Issue persisted after repair.
Recalls/TSBs owners mention: Ford zone representative stated A-pillar has 'no safety impact.' Open case filed but unresolved at time of complaint.
Water intrusion into passenger-side floorboard and interior corrosion
Rain and moisture penetration into vehicle interior, particularly passenger-side floorboard. Rust forming on metal parts in glove box. Odor from water buildup in air vent system. Pattern reported across multiple Sable and Taurus vehicles per owner.
When: 17,000 miles; purchased at 247 miles; warranty expired at time of complaint
Symptoms owners cite: Soaked passenger-side floorboard after rain; Rust on metal parts in glove box; Drip stains in glove box; Odor from air vents
Repairs/costs cited: One narrative mentions weather stripping cowl panel failure and leaking air intake heater box requiring cowl panel replacement (failure at 43,917 miles). Dealer repair attempts unsuccessful; independent mechanic unable to diagnose.
Recalls/TSBs owners mention: No official recall. Dealer initially attributed to normal moisture; later declined warranty coverage citing $100 investigation fee and claiming issue outside warranty scope.
Door latch freezing in cold weather
Driver and passenger door latches freeze in cold temperatures (below 20°F), preventing doors from closing or causing them to spontaneously open while vehicle is in motion or running. Multiple occurrences reported during same complaint season.
When: January 2012–2013 cold weather events
Symptoms owners cite: Door latches freeze and will not close; Door spontaneously opens while driving; Doors lock while engine running (owners warming up vehicle)
Repairs/costs cited: One owner reports latch replacement on second vehicle two years prior. No repair documented for affected vehicle.
Recalls/TSBs owners mention: None documented in narratives.
Static electricity discharge hazard
Vehicle shocks occupants when exiting either side. Dealer attempted wax coating and recommended static guard spray without resolution.
When: Early ownership
Symptoms owners cite: Electrical shock when exiting vehicle from either side
Repairs/costs cited: Wax coating applied to vehicle; static guard spray applied to seats multiple times. Neither resolved issue.
Recalls/TSBs owners mention: Ford case opened (case no. 5EDN4008, dated 5/4/05); manufacturer stated 'nothing that could be done about it.' No service records maintained by dealer.
Extensive floor pan rust perforation
Multiple large rust-through holes in floor pans across vehicle. Passenger-side floor pan completely rusted through; driver-side pan has ~8" hole; rear passenger pan has ~10" hole. Only carpet prevented occupant contact with road surface.
When: Later in vehicle service life (one vehicle at 75,000 miles failed inspection)
Symptoms owners cite: Visible holes in passenger, driver, and rear passenger floor pans; Complete perforation of passenger-side floor pan; Vehicle frame rust documented
Repairs/costs cited: No repairs documented. Vehicle deemed unsafe to drive.
Recalls/TSBs owners mention: None documented.
Frame rust deterioration
Frame rust-out rendering vehicle unsafe for continued operation at 75,000 miles.
When: 75,000 miles
Symptoms owners cite: Frame rusted out per inspection
Repairs/costs cited: Vehicle failed state inspection; declared unsafe to drive.
Recalls/TSBs owners mention: None documented.
Paint bubbling and peeling
Paint failure on roof, front bumper, and rear bumper with bubbling and peeling.
When: Not specified
Symptoms owners cite: Paint bubbling on roof, front bumper, and rear bumper; Paint peeling on roof, front bumper, and rear bumper
Repairs/costs cited: No repairs documented.
Recalls/TSBs owners mention: None documented.
Trunk latch failure
Trunk opened spontaneously while vehicle was in motion without occupant input.
When: Not specified
Symptoms owners cite: Trunk opened on its own while driving; Heard click prior to opening; no button pressed
Repairs/costs cited: No repairs documented.
Recalls/TSBs owners mention: None documented.
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
After it rains, the passenger side floorboard is soaked. There is also rust on the metal parts in the glove box as well as drip stains. I have reported this several times to the dealer since I purchased the car and was told it is just moisture causing the rust (such a lie). They said the smell in the vents was caused by a small build up of water in the air vent reservoir. I have only 17,000…
Tl* the contact owns a 2005 Ford taurus. The contact stated that the driver's side floor board was rusted out. The vehicle was taken to a dealer where it was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.
Had body trouble with your 2005 Ford Taurus?
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 body problem on the 2005 Ford Taurus?
It's a meaningful issue. 17 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Across the 11 complaints that reported odometer mileage, most body failures cluster between 67,000 and 150,000 miles, with the median around 103,000. A quarter of owners report trouble before 67,000; a quarter make it past 150,000. 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 $1,500 for body 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 body?
No active recalls currently cover body 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/Taurus.
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.