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full bulletin at NHTSA ↗2006 Ford Five Hundred engine problems
severe 25 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
25
Recalls
0
Avg fix
$3,100
1crash
1fire
What stands out
Owners have filed 25 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
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.
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗MIL WITH DTC P0106 AND/OR P0109.
full bulletin at NHTSA ↗WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING.
full bulletin at NHTSA ↗ENGINE RPM FLUCTUATION AT HIGHWAY CRUISING SPEEDS - VEHICLES BUILT PRIOR TO 8/2/2005.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 Ford Five Hundred exhibits a pattern of engine control faults that create real safety hazards. The throttle body malfunctions are the biggest complaint: owners report the vehicle lurches or surges forward—sometimes backward in reverse—without warning, even with the brake pedal fully depressed. This happens at stop lights, when shifting out of park, or after running the air conditioner. In several cases, the vehicle lunged into curbs or nearly hit pedestrians. Dealers often cannot replicate the issue in the shop, leaving owners without warranty coverage.
Stalling is another recurring problem. Engines die without warning at highway speeds, wrench lights come on, and restarts are required. EGR valve replacement doesn't always fix it; throttle body service usually does, but costs $560–$1600 once the factory warranty expires.
A/C compressor failures are widespread and predictable: the system cools only at highway speeds above 60 mph. In town, it blows hot air. Recharges and sensor replacements don't help. Ford acknowledges the complaints but refuses warranty coverage.
Motor mounts crack or dry-rot, and one owner's manifold caught fire. Transmission problems show up too—CVT failures requiring replacement within the first two years of ownership in at least one case.
Cold weather seems to trigger electrical and drivetrain faults simultaneously, and fuel economy consistently runs 2–5 mpg below EPA estimates, sometimes worsening despite repairs.
Same Ford Five Hundred engine reports on nearby years: 2005 · 2007
Failure modes owners describe
Throttle body malfunction with unintended acceleration
Throttle body fails or sticks, causing the engine to surge, lunge forward, or accelerate uncontrollably even with brake pedal applied. Occurs at stop lights, when shifting into gear, or at idle. Safety hazard when vehicle lunges into pedestrians, other vehicles, or curbs.
When: Intermittent; occurs most with A/C running, in cold weather, or when shifting out of park. Complaints spanning 2009–2013.
Symptoms owners cite: Vehicle lurches or lunges forward unexpectedly; Vehicle surges backward when in reverse with brake applied; Engine RPMs spike when shifting from park to drive or drive to park; Throttle unresponsive or stuck in idle position; Wrench light and check engine light illuminate; Can occur with foot on brake; brake ineffective at preventing lunge
Codes mentioned: Throttle stuck closed, Throttle forced to idle (safety limp mode), Throttle actuator control system fault, Alternative fuel control module fault
Repairs/costs cited: Throttle body replacement: $560–$970. Some owners cite induction carbon flush as added service ($1000+ total). Motor mounts sometimes replaced in conjunction ($600–$1600 total). MAF sensor and EGR valve replacement attempted in some cases without resolving throttle surge.
Recalls/TSBs owners mention: Service bulletin R12N03 issued offering free repair; coverage ended 03/31/2013. Some owners claim warranty denied after coverage window closed. Dealer service often unable to replicate issue in shop, denying warranty coverage.
A/C compressor failure; only functions at highway speed
A/C compressor fails to cool adequately at idle or low speed; only produces cold air when vehicle travels at highway speeds (60+ mph). Multiple owners report recharge and thermostat replacement without resolution. Appears widespread in this model.
When: Reported from purchase through ~45,000–50,000 miles; pattern consistent across multiple model years.
Symptoms owners cite: A/C blows hot air in town driving; A/C only blows cold above ~60 mph; System intermittently loses cooling; Problem persists after recharge and component checks
Repairs/costs cited: Recharge and low/high-side pressure valve checks performed without success. Thermostat replaced. Compressor replacement quoted but not detailed in price. One owner reports mechanic stated this is a known problem for the model.
Recalls/TSBs owners mention: Ford acknowledges multiple complaints but refuses warranty coverage; advises owner to keep receipts in case Ford later decides to cover it. No recall issued.
Engine stalling and loss of power while driving
Engine stalls suddenly while driving at highway speed or stops abruptly with wrench light illuminated. Stalling occurs repeatedly and sometimes resolves after restart, but vehicle remains undrivable until restart.
When: Reported at 30–127,500 miles; some owners have experienced surging/stalling issues since purchase.
Symptoms owners cite: Engine stalls without warning while driving 30–65 mph; Loss of throttle response; RPM drops below 1000; Wrench light and check engine light illuminate; Vehicle lurches forward then appears to shut down; Restart restores normal operation temporarily or long-term
Codes mentioned: EGR valve fault, Throttle stuck closed, Throttle forced to idle
Repairs/costs cited: EGR valve replacement performed in one case without resolving stall. Throttle body replacement and vacuum hose replacement helped one owner after MAF sensor and EGR valve swaps failed ($1600 total). PCM and TCM update and upper motor mount replacement performed in another case.
Recalls/TSBs owners mention: Manufacturer notification received; no recall coverage cited. Warranty denied on out-of-coverage vehicles.
Manifold fire and dry-rotted motor mount
Top of engine manifold ignites during driving at moderate speed; motor mount is severely dry-rotted. Owner extinguished fire with personal extinguisher.
When: Mileage unknown; vehicle still operational after fire.
Symptoms owners cite: Burning odor detected while driving ~40 mph; Manifold ignites into flames; Motor mount visibly dry-rotted
Repairs/costs cited: Motor mount replacement needed per independent mechanic. Repair not completed; no cost provided.
Recalls/TSBs owners mention: Manufacturer not notified.
Idle RPM surge and erratic behavior after cold start or shift
Engine RPM surges from 2000–3500 unexpectedly in cruise control on flat road, or RPM surges as high as 2500 when shifting park to drive. Can occur repeatedly within a drive cycle.
When: Intermittent, worsening over time. One long-distance travel case resolved after 100 miles.
Symptoms owners cite: RPM climbs on its own during cruise control; RPM surge when shifting between gears; Low idle speed at traffic lights, sometimes stalling; Engine surge when turning into parking spots
Repairs/costs cited: No repairs detailed for isolated RPM surge; one owner notes throttle body and motor mount replacement recommended.
Recalls/TSBs owners mention: One owner references R12N03 warranty letter not received; coverage ended 03/31/2013 without repair being performed.
Poor fuel economy; degradation below EPA estimate
Fuel economy consistently below manufacturer estimate, ranging 12–17 mpg combined city/highway despite good maintenance. Defective EVAP hose temporarily restored efficiency.
When: Chronic issue from purchase through at least 50,000+ miles.
Symptoms owners cite: Combined mpg never exceeds 17 (well below EPA estimates); Degradation to 12 mpg over time; Brief recovery to 17 mpg after EVAP hose replacement, then decline to 13 mpg again
Repairs/costs cited: EVAP hose/fitting replacement performed; brief improvement followed by decline. Dealership unable to permanently remedy.
Recalls/TSBs owners mention: None documented.
Transmission issues and limp-mode behavior
CVT transmission fails to engage properly or goes into reverse unexpectedly with loud bang. In one case, vehicle exhibits multiple electrical and drivetrain warning lights after cold-weather exposure, preventing transmission from changing gears in drive.
When: After 1050 miles on long trip in cold/snow conditions; another owner replaced transmission ~2 years after purchase (under warranty).
Symptoms owners cite: Transmission warning light illuminates; vehicle won't shift gears in drive; CVT goes into reverse with loud bang and vibration; Multiple lights illuminate (transmission, ABS, traction control, check engine); Lights cycle off and on with restarts
Repairs/costs cited: One transmission replacement performed under warranty ~2 years into ownership. Cold-weather event resolved after 650+ miles and multiple restarts.
Recalls/TSBs owners mention: Dealer blamed cold weather and snow; claimed AWD and traction control should handle such conditions.
Synthesized from 25 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2006 Ford Five Hundred?
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 2006 Ford Five Hundred?
It's a meaningful issue. 25 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 22 complaints that reported odometer mileage, most engine failures cluster between 49,647 and 111,345 miles, with the median around 70,000. A quarter of owners report trouble before 49,647; a quarter make it past 111,345. 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 $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/2006/Ford/Five Hundred.
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.